Void-containing layer, laminate, method for producing void-containing layer, optical member, and optical apparatus

ABSTRACT

A void-containing layer is disclosed in which a pressure-sensitive adhesive or an adhesive is less likely penetrated into voids. The void-containing layer of the present invention includes: nanoparticles, surfaces of which are modified with a compound having a surface orientation, wherein the void-containing layer has a void fraction of 35 vol %.

TECHNICAL FIELD

The present invention relates to a void-containing layer, a laminate, amethod for producing a void-containing layer, an optical member, and anoptical apparatus.

BACKGROUND ART

In an optical device, for example, an air layer having a low refractiveindex is used as a total reflection layer. Specifically, for example,optical film members (e.g., a light guide plate and a reflector) in aliquid crystal device are laminated with an air layer interposedtherebetween. However, when the respective members are separated fromeach other by an air layer, particularly in a case where the members arelarge in size, problems such as distortion of the members may arise. Inaddition, due to trends toward thinner devices, it is desired tointegrate the respective members. For this reason, the respectivemembers are integrated by a pressure-sensitive adhesive/adhesive withoutan air layer interposed therebetween (Patent Literature 1). However, ifthere is no air layer serving as a total reflection layer, opticalcharacteristics may become poor, which causes light leakage.

Therefore, it has been proposed to use a low refractive index layerinstead of an air layer. For example, Patent Literature 2 describes astructure in which a light guide plate and a reflector are laminated viaa layer having a lower refractive index than that of the light guideplate. As the low refractive index layer, for example, a void-containinglayer having voids is used in order to make the refractive index low asclose as possible to air.

CITATION LIST Patent Literature

Patent Literature 1: JP 2012-156082 A

Patent Literature 2: JPH10(1998)-62626 A

SUMMARY OF INVENTION Technical Problem

For example, the void-containing layer is laminated on another layerwith a pressure-sensitive adhesive/adhesive layer interposedtherebetween to use. However, when laminating the void-containing layerand the pressure-sensitive adhesive/adhesive layer, thepressure-sensitive adhesive or adhesive constituting thepressure-sensitive adhesive/adhesive layer may penetrate into the voidsof the void-containing layer to fill the voids, which lowers the voidfraction. The higher the void fraction of the void-containing layer, themore likely the pressure-sensitive adhesive or adhesive will penetrate.In a high-temperature environment, the pressure-sensitive adhesive oradhesive is prone to penetrate into the voids by the molecular motion ofthe pressure-sensitive adhesive or adhesive.

In order to suppress or prevent the penetration of thepressure-sensitive adhesive or adhesive into the voids, thepressure-sensitive adhesive or the adhesive having an elastic modulus ashigh as possible (hard) may be used. However, if the elastic modulus ofthe pressure-sensitive adhesive or adhesive is high (hard), thepressure-sensitive adhesive force or the adhesive force may be lowered.Conversely, if the elastic modulus of the pressure-sensitive adhesive oradhesive is low (soft), although a high pressure-sensitive adhesiveforce or an adhesive force is readily obtained, the pressure-sensitiveadhesive or adhesive may be prone to penetrate into the voids.

In order to suppress or prevent the penetration of thepressure-sensitive adhesive or the adhesive into the voids, for example,it is conceivable to form a layer (penetration suppressing layer) thatcan suppress the penetration of the pressure-sensitive adhesive or theadhesive on the void-containing layer by using a substance other thanthe pressure-sensitive adhesive or the adhesive. In that case, however,the step of forming the penetration suppressing layer is requiredseparately from the step of forming the void-containing layer, whichincreases the number of manufacturing processes.

For these reasons, required is a void-containing layer in which apressure-sensitive adhesive or an adhesive is less likely penetratedinto voids.

Accordingly, it is an object of the present invention to provide avoid-containing layer in which a pressure-sensitive adhesive or anadhesive is less likely penetrated into voids, to also provide alaminate including the void-containing layer, a method for producing thevoid containing layer, and an optical member and an optical apparatusincluding the void-containing layer.

Solution to Problem

In order to achieve the above object, the present invention provides avoid-containing layer including: nanoparticles, surfaces of which beingmodified with a compound having a surface orientation, wherein thevoid-containing layer has a void fraction of 35 vol %.

The present invention also provides a laminate obtained by directlylaminating the void-containing layer according to the present inventionand a pressure-sensitive adhesive/adhesive layer.

The present invention also provides a method for producing thevoid-containing layer according to the present invention, including thesteps of coating a dispersion comprising the nanoparticles, and dryingthe coated dispersion.

The present invention also provides an optical member including: thelaminate according to the present invention.

The present invention also provides an optical apparatus including: theoptical member according to the present invention.

Advantageous Effects of Invention

The present invention can provide a void-containing layer in which apressure-sensitive adhesive or an adhesive is less likely penetratedinto voids, can also provide a laminate unending the void-containinglayer, a method for producing the void-containing layer, and an opticalmember and an optical apparatus including the void-containing layer.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a cross-sectional view schematically illustrating an exampleof a process of a method for forming a laminate of the present inventionin which a void-containing layer 21, an intermediate layer 22, and apressure-sensitive adhesive/adhesive layer 30 are laminated on a resinbase 10.

FIG. 2 is a schematic view showing an example of some steps in a methodfor producing a laminated film in the form of a roll (“laminated filmroll”) and an apparatus used in the method.

FIG. 3 is a schematic view showing another example of some steps in amethod for producing a laminated film roll and an apparatus used in themethod.

FIG. 4 is a cross-sectional photograph of the laminate produced inExample 1.

FIG. 5 is a cross-sectional photograph of the laminate produced inComparative Example 1.

FIG. 6 is a cross-sectional photograph of the laminate produced inComparative Example 2.

DESCRIPTION OF EMBODIMENTS

The present invention will be described more specifically below withreference to illustrative examples. It is to be noted, however, that thepresent invention is by no means limited by the following descriptions.

In the void-containing layer of the present invention, for example, thecompound having the surface orientation may be an alkoxysilanederivative, and the alkoxysilane derivative may contain a fluoroalkylgroup having 5 to 17 or 5 to 10 fluorine atoms. The fluoroalkyl groupmay be an alkyl group in which only a part of hydrogen is substitutedwith fluorine, or may be an alkyl group (perfluoroalkyl group) in whichall hydrogen is substituted with fluorine.

The void-containing layer of the present invention may contain, forexample, 10 to 50 mass % of the nanoparticles relative to a skeletoncomponent of the void-containing layer.

In the method for producing a void-containing layer of the presentinvention, for example, a layer composed of the nanoparticles may beformed inside the void-containing layer while forming thevoid-containing layer.

In the void-containing layer of the present invention, apressure-sensitive adhesive or an adhesive are less likely penetratedinto the voids, Therefore, it is not necessary to form a separatepenetration suppressing layer, and the void-containing layer of thepresent invention and a pressure-sensitive adhesive/adhesive layer canbe directly laminated. Therefore, an increase in the number ofmanufacturing processes due to the step of forming the penetrationsuppressing layer can be avoided.

The reason (mechanism) why a pressure-sensitive adhesive or an adhesiveare less likely penetrated into voids in the void-containing layer ofthe present invention is considered as follows, for example. First, thesurface orientation (migration to an air interface) of a compound havinga surface orientation (e.g., a compound having perfluoroalkyl) isutilized to impart the surface orientation to nanoparticles themselves,the surfaces of which have been modified with the compound. Here, thesurface modification of the void-containing layer can be performedsimply by the compound having the surface orientation, but it is notenough to suppress the macroscopic penetration of the pressure-sensitiveadhesive. Therefore, the nanoparticles till the voids on the outermostsurface of the void-containing layer to physically suppress thepenetration of the pressure-sensitive adhesive or the adhesive. However,since nanoparticles, surfaces of which are not modified, have no surfaceorientation, they are just present in the void-containing, layer and donot orient on the surface of the void-containing layer, which does notbring about a penetration suppressing effect. By modifying thenanoparticles with a compound having a surface orientation, thenanoparticles have surface orientation to the void-containing layer.Thereby, as described above, the nanoparticles fill the voids in theoutermost surface of the void-containing layer to physically suppressthe penetration of the pressure-sensitive adhesive or the adhesive. Thatis, the nanoparticles modified with a compound having a surfaceorientation fill the voids in the outermost surface of thevoid-containing layer, thereby forming a penetration suppressing layeron the outermost surface (surface layer) relative to thepressure-sensitive adhesive or the adhesive. Thus, as described above,the step of forming a separate penetration suppressing layer isunnecessary, and an increase in the number of manufacturing: processesdue to the step of forming the penetration suppressing layer can beavoided. It is to be noted, however, that these mechanisms merely areexamples and do not limit the present invention by any means. In orderto produce the void-containing layer of the present invention, forexample, as described below, nanoparticles modified With a compoundhaving a surface-orientation may be added to a coating solution forforming a void-containing layer.

1. Void-Containing Layer, Laminate, Optical Member, and OpticalApparatus

The void-containing layer of the present invention includesnanoparticles, surfaces of which are modified with a compound having asurface orientation, wherein the void-containing layer has a voidfraction of 35 vol %, as described above. In the laminate of the presentinvention, as described above, the void-containing layer of the presentinvention and a pressure-sensitive adhesive/adhesive layer are directlylaminated. The pressure-sensitive adhesive/adhesive layer may belaminated on one side or both sides of the void-containing layer of thepresent invention. In the present invention, with reference to “thepressure-sensitive adhesive/adhesive layer is “directly laminated” onthe void-containing layer”, the pressure-sensitive adhesive/adhesivelayer may be directly contacted with the void-containing layer, thepressure-sensitive adhesive/adhesive layer may be laminated on thevoid-containing layer through a layer (penetration suppressing layer)formed of nanoparticles (nanoparticles, surfaces of which are modifiedwith a compound having a surface orientation) in the void-containinglayer, or the pressure-sensitive adhesive/adhesive layer may belaminated on the void-containing layer through an intermediate layerformed by combining the void-containing layer and the pressure-sensitiveadhesive/adhesive layer.

In the present invention, the light transmittance of the void-containinglayer of the present invention or the laminate of the present inventionmay be 80% or more. For example, the haze of the void-containing layerof the present invention or the laminate of the present invention may be3% or less. The light transmittance may be, for example, 82% or more,84% or more, 86% or more, or 88% or more, and the upper limit is notparticularly limited, but is ideally 100%, and may be, for example, 95%or less, 92% or less, 91% or less, or 90% or less. The haze of thevoid-containing layer of the present invention or the laminate of thepresent invention can be measured for example, by the haze measurementmethod described below. The light transmittance is a transmittance oflight having a wavelength of 550 nm, and can be measured by, forexample, the following measurement method.

(Measurement Method of Light Transmittance)

A spectrophotometer U-4100 (trade name, manufactured by Hitachi, Ltd.)is used, and the laminate is used as a sample to be measured. The totallight transmittance (light transmittance) of the sample is measured withthe total light transmittance of air being considered to be 100%. Thevalue of the total light transmittance (light transmittance) is a valuemeasured at a wavelength of 550 nm.

In the laminate of the present invention, for example, thepressure-sensitive adhesive/adhesive layer may have a pressure-sensitiveadhesive force or an adhesive force of 0.7 N/25 mm or more, 0.8 N125 mmor more, 1.0 N/25 mm or more, or 1.5 N/25 mm or more, and 50 N/25 mm orless, 30 N/25 mm or less, 10 N/25 mm or less, 5 N/25 mm or less, or 3N/25 mm or less. From the viewpoint of risks of peeling off at the timeof handling when the laminate is adhered to other layers, it ispreferable that the pressure-sensitive adhesive force or the adhesiveforce of the pressure sensitive adhesive/adhesive layer be not too low.In addition, from the viewpoint of rework at the time of reattachment,it is preferable that the pressure-sensitive adhesive force or theadhesive force of the pressure-sensitive adhesive/adhesive layer be nottoo high. The pressure-sensitive adhesive force or the adhesive force ofthe pressure-sensitive adhesive/adhesive layer can be measured, forexample, as follows.

(Measurement Method of Pressure-Sensitive Adhesive Force or AdhesiveForce)

From the laminated film of the present invention (film in which thelaminate of the present invention is formed on a resin film base), astrip-shaped piece with a size of 50 mm×40 mm is obtained as a sample,and the sample is fixed to a stainless plate with a double-sided tape.An acrylic pressure-sensitive adhesive layer (thickness: 20 μm) isadhered to a PET film (T100: manufactured by Mitsubishi Plastics, Inc.),and the thus-obtained adhesive tape is cut into a piece with a size of25 mm×100 mm. The thus-obtained cut piece is adhered to the oppositeside of the resin film in the laminated film of the present invention toform a laminate of the PET film and the laminated film. Then, the sampleis chucked in an autograft tensile testing machine (AG-Xplus,manufactured by Shimadzu Corporation) with a distance between chucksbeing 100 mm, and the tensile test is performed at a tensile speed of0.3 m/min. The mean value of the peel test data for 50 mm is set as thepeel adhesion strength, i.e., pressure-sensitive adhesive force. Theadhesive force can also be measured by the same measurement method. Inthe present invention, there is no clear distinction between the“pressure-sensitive adhesive force” and the “adhesive force”.

The laminate of the present invention may be formed on a base such as,for example, a film. The film may be, for example, a resin film.Regarding the “film” and the “sheet”, generally, the one having arelatively small thickness is called a “film” and the one having arelatively large thickness is called a “sheet” in some cases, however,in the present invention, there is no particular distinction between the“film” and the “sheet”.

The base is not limited to particular bases, and for example, a basemade of a thermoplastic resin, a base made of glass, an inorganic baseplate typified by silicon, a plastic formed of a thermosetting resin, anelement such as a semiconductor, or a carbon fiber-based materialtypified by carbon nanotube can be favorably used. The base, however, isby no means limited thereto. Examples of the form of the base include afilm and a plate. Examples of the thermoplastic resin includespolyethylene terephthalate (PET), acrylic resins, cellulose acetatepropionate (CAP), cycloolefin polymer (COP), triacetylcellulose (TAC),polyethylene naphthalate (PEN) polyethylene (PE), and polypropylene(PP).

The optical member of the present invention is not particularly limited,and may be, for example, an optical film including the laminate of thepresent invention.

The optical apparatus (optical device) of the present invention is notparticularly limited, and may be, for example, an image display device,an illumination device, or the like. Examples of the image displaydevice include a liquid crystal display, an organic electro luminescence(EL) display, and a micro light emitting diode (LED) display. Theillumination device may be, for example, an organic EL illumination, orthe like.

2. Void-Containing Layer

The void-containing layer in the laminate of the present invention(hereinafter also referred to as the “void-containing layer of thepresent invention”) will be described below with reference to examples.It is to be noted, however, that the void-containing layer of thepresent invention is not limited thereto.

The void-containing layer of the present invention may have, forexample, a void fraction of 35 vol % or more and a peak pore diameter of50 nm or less. However, this merely is an example, and thevoid-containing layer of the present invention is not limited thereto.

The void fraction may be, for example, 35 vol % or more, 38 vol % ormore, or 40 vol % or more, and 90 vol % or less, 80 vol % or less, or 75vol % or less. The void-containing layer of the present invention maybe, for example, a highly void-containing layer having a void fractionof 60 vol % or more.

The void fraction can be measured, for example, by the followingmeasurement method.

(Measurement Method of Void Fraction)

If the layer whose void fraction is to be measured is a single layercontaining voids, the ratio (volume ratio) between the component of thelayer and the air can be calculated by a standard method (for example,weight and volume are measured to calculate the density), whereby thevoid fraction (vol %) can be calculated. Further, since the refractiveindex and the void fraction have a correlation, the void fraction can becalculated from the value of the refractive index as, a layer, forexample. Specifically, for example, the void fraction is calculatedaccording to the Lorentz-Lorenz's formula from the value of therefractive index measured by an ellipsometer.

The void-containing layer of the present invention can be produced, forexample, by chemical bonding of gel pulverized products (microporousparticles) as will be described below. In this case, the voids of thevoid-containing layer can be divided into three types (1) to (3) belowfor convenience.

(1) Voids contained in raw material gel itself (inside the particles)

(2) Voids contained in gel pulverized product unit

(3) Voids between gel pulverized products created by deposition of gelpulverized products

The voids (2) are voids formed during pulverization, which are differentfrom the voids (1) that can be formed in each block when each particlegroup generated by pulverizing the gel is regarded as one mass (block)regardless of the size or the like of the gel pulverized product(microporous particle). The voids (3) are voids created because ofirregularity in the sizes or the like of the gel pulverized products(microporous particles) in pulverization (e.g., media-lesspulverization). The void-containing layer of the present inventioncontains the voids (1) to (3), whereby an appropriate void fraction andpeak pore diameter can be achieved, for example.

The peak pore diameter may be, fix example, 5 nm or more, 10 nm or more,or 20 nm or more, and 50 nm or less, 40 nm or less, or 30 nm or less. Inthe void-containing layer, if the peak pore diameter is too large in astate where the void fraction is high, light is scattered, which makesthe void-containing layer opaque. Further, in the present invention, thelower limit value of the peak pore diameter of the void-containing layeris not particularly limited, but it is preferable that the peak porediameter is not too small because it is difficult to increase the voidfraction if the peak pore diameter be too small. In the presentinvention, the peak pore diameter can be measured, for example, by thefollowing method.

(Measurement Method of Peak Pore Diameter)

The peak pore diameter is calculated from the results of the BJH plotand the BET plot by nitrogen adsorption and the isothermal adsorptionline using a pore distribution/specific surface area analyzer (tradename: BELLSORP MINI, MicrotracBEL Corp.).

The void-containing layer of the present invention includesnanoparticles, surfaces of which are modified with a compound having asurface orientation, as described above. The nanoparticles will bedescribed in detail below. The void-containing layer may include, forexample, 10 to 50 mass %, 15 to 40 mass %, or 20 to 30 mass % of thenanoparticles relative to a skeleton component of the void-containinglayer. In the void-containing layer of the present invention, the“skeleton component” means a component having the largest mass amongcomponents forming the void-containing layer of the present inventionother than air. When the void-containing layer of the present inventionis a silicone porous body, the “skeleton component” in thevoid-containing layer of the present invention is a condensation productof monoalkyl (trimethoxy)silane, for example.

The thickness of the void-containing layer of the present invention isnot particularly limited, and may be, for example, 100 nm or more, 200nm or more, or 300 nm or more, and 10000 nm or less, 5000 nm or less, or2000 nm or less.

The void-containing layer of the present invention uses pulverizedproducts of the porous gel material, for example. Thus, thethree-dimensional structure of the porous gel material is destroyed,whereby a new three-dimensional structure different from that of theporous gel material is formed. As will be described below, thevoid-containing layer of the present invention becomes a layer having anew pore structure (new void-containing structure) that cannot beobtained in a layer formed using the porous gel material. That is, anano-scale void-containing layer having a high void fraction can beformed. Moreover, for example, when the void-containing layer of thepresent invention is a silicone porous material, the pulverized productsin the void-containing layer are chemically bonded to each other whileadjusting the number of functional groups having siloxane bonds of thesilicon compound gel, for example. Furthermore, a new three-dimensionalstructure is formed as a void-containing layer precursor, and pulverizedproducts are thereafter bonded chemically (e.g., crosslinked) to eachother in the bonding step. Thus, when the void-containing layer of thepresent invention is a void-containing layer, the void-containing layerhas a structure with void spaces, for example. However, it can maintaina sufficient strength and sufficient flexibility. Therefore, accordingto the present invention, the void-containing layer can be easily andsimply applied to various objects.

For example, the void-containing layer of the present invention includespulverized products of a porous gel material as will be described below,and the pulverized products are chemically bonded to each other. In thevoid-containing layer of the present invention, the form of the chemicalbonding (chemical bonds) between the pulverized products is not limitedto particular forms. Specifically, the chemical bonds may becrosslinking bonds, for example. The method for chemically bonding thepulverized products to each other is as described in detail in, forexample, the method for producing the void-containing layer describedabove.

The crosslinking bonds are siloxane bonds, for example. Examples of thesiloxane bonds include T2, T3, and T4 bonds shown below. When thesilicone porous material of the present invention includes siloxanebonds, the silicone porous material may include any one of the T2, T3,and T4 bonds, any two of them, or all three of them, for example. As theproportions of T2 and T3 among the siloxane bonds become higher, thesilicone porous as material becomes more flexible, so that it isexpected that the silicone porous material exhibits characteristicsintrinsic to the gel. However, the film strength of the silicone porousmaterial is deteriorated. When the proportion of T4 in the siloxanebonds becomes higher, a film strength is more likely to be obtained,whereas void spaces become smaller, resulting in deterioratedflexibility. Thus, it is preferable to adjust the proportions of T2, T3,and T4 depending on the intended use of the silicone porous material,for example.

In the case where the void-containing layer of the present inventionincudes the siloxane bonds, the ratio of T2, T3, and T4 expressedrelatively assuming that the proportion of T2 is “1” is as follows, forexample: T2:T3:T4=1:[1 to 100]:[0 to 50], 1:[1 to 80]:[1 to 40], or 1:[5to 60]:[1 to 30].

It is preferable that silicon atoms contained in the void-containinglayer of the present invention be bonded to each other through siloxanebonds, for example. As a specific example, the proportion of unbondedsilicon atoms (i.e., residual silanol) among all the silicon atomscontained in the silicone porous material is less than 50%, 30% or less,or 15% or less, for example.

The void-containing layer of the present invention has a pore structure.In the present invention, the size of each void space in the porestructure indicates, out of the diameter of the long axis and thediameter of the short axis of the void space (pore), the diameter of thelong axis. The size of the void space (pore) is from 5 nm to 50 nm, forexample. The lower limit of the size is, for example, 5 nm or more, 10nm or more, or 20 nm or more. The upper limit of the size is, forexample, 50 nm or less, 40 nm or less, or 30 nm or less. The range ofthe size is, for example, from 5 nm to 50 nm or from 10 nm to 40 nm. Apreferable size of the void spaces is determined depending on the use ofthe void-containing structure. Thus, it is necessary to adjust the sizeof the void spaces to a desired value according to the intended use, forexample. The size of the void spaces can be evaluated in the followingmanner, for example.

(SEM Observation of Cross Section of Void-Containing Layer)

In the present invention, the void-containing layer can be observed andanalyzed using a scanning electron microscopy (SEM). Specifically, forexample, the void-containing layer is subjected to FIB processing(acceleration voltage: 30 kV) while being cooled, and thecross-sectional electronic image of the obtained cross-sectional samplecan be obtained by FIB-SEM (trade name: Helios NanoLab 600, manufacturedby FEI Compaly, acceleration voltage: 1 kV) at an observingmagnification of 100,000×.

(Evaluation of Size of Void Spaces)

In the present invention, the size of the void spaces can be quantifiedaccording to the BET test. Specifically, 0.1 g of a sample (thevoid-containing layer of the present invention) is set in a capillarytube of a pore distribution/surface area measurement apparatus (tradename: BELLSORP MIN, manufactured by MicrotracBEL Corp.), and dried underreduced pressure at room temperature for 24 hours to remove gas in thevoid-containing structure. Then, a BET plot, a BJH plot, and anadsorption isotherm are created by causing the sample to adsorb nitrogengas, whereby the pore distribution is determined. On the basis of thethus-determined pore distribution, the size of the void spaces can beevaluated.

The void-containing layer of the present invention may have, forexample, a pore structure (porous structure) as mentioned above, and thepore structure may be an open-cell structure in which pores areinterconnected with each other, for example. The open-cell structuremeans that, for example, in the low refractive index layer, poresthree-dimensionally communicate with each other. In other words, theopen-cell structure means the state where void spaces inside the porestructure are interconnected with each other. When a porous material hasan open-cell structure, this structure allows the bulk body to have ahigher void fraction. However, in the case where closed-cell particlessuch as hollow silica particles are used, an open-cell structure cannotbe formed. In contrast, in the void-containing layer of the presentinvention, an open-cell structure can be formed easily for the followingreason. Sol particles (pulverized products of a porous gel material forforming a sol) each have a dendritic structure, so that the open-cellstructure is formed as a result of sedimentation and deposition of thedendritic particles in a coating film (a coating film formed of a solcontaining pulverized products of the porous gel material). Further, itis more preferable that the void-containing layer of the presentinvention form a monolith structure, which is an open-cell structureincluding two or more types of micropore distributions. The monolithstructure refers to a layered structure including a structure in whichnano-sized void spaces are present and an open-cell structure formed byaggregation of the nano-sized spaces, for example. When the monolithstructure is formed, for example, the film strength is imparted by theminute void spaces whereas a high void fraction is achieved by thepresence of the void spaces forming a bulky open-cell structure. Thus,both a film strength and a high void fraction can be attained. In orderto form such a monolith structure, for example, first, in the porous gelmaterial before being pulverized into the pulverized products, it ispreferable to control the micropore distributions in a void-containingstructure to be generated. Also, the monolith structure can be formedby, for example, controlling, at the tune of pulverizing the porous gelmaterial, the particle sizes of the pulverized products so that adesired particle size distribution can be obtained.

In the void-containing layer of the present invention, the haze valueindicating the transparency is not particularly limited. The lower limitof the haze is, for example, 0.1% or more, 0.2% or more, or 0.3% ormore. The upper limit of the haze is, for example, 10% or less, 5% orless, or 3% or less. The range of the haze value is, for example, from0.1% to 10%, from 0.2% to 5%, or from 0,3% to 3%.

The haze value can be measured in the following manner, for example.

(Evaluation of Haze Value)

A void-containing layer (the void-containing layer of the presentinvention) is cut into a piece with a size of 50 mm×50 mm, and thethus-obtained cut piece is set in a haze meter (HM-150, manufactured byMurakami Color Research Laboratory) to measure the haze value. The hazevalue is calculated by the following formula.Haze value (%)=[diffuse transmittance (%)/total light transmittance(%)]×100(%)

The “refractive index” of a given medium generally refers to the ratioof transmission speed of the wavefront of light in vacuum to the phasevelocity of the light in the medium. The refractive index of thevoid-containing layer of the present invention is not particularlylimited, and the upper limit thereof is, for example, 1.3 or less, lessthan 1.3, 1.25 or less, 1.2 or less, or 1.15 or less, the lower limitthereof is, for example, 1.05 or more, 1.06 or more, or 1.07 or more,and the range thereof is, for example, 1.05 or more and 1.3 or less,1.05 or more and less than 1.3, 1.05 or more and 1.25 or less, 1.06 ormore and less than 1.2, or 1.07 or more and 1.15 or less.

In the present invention, the refractive index refers to the onemeasured at a wavelength of 550 nm, unless otherwise stated. The methodfor measuring the refractive index is not particularly limited. Forexample, the refractive index can be measured in the following manner.

(Evaluation of Refractive Index)

A void-containing layer (the void-containing layer of the presentinvention) is formed on an acrylic film, and the obtained laminate isthen cut into a piece with a size of 50 mm×50 mm. The thus-obtained cutpiece is adhered onto a surface of a glass plate (thickness: 3 mm) witha pressure-sensitive adhesive layer. The central portion (diameter:about 20 mm) of the back surface of the glass plate is painted entirelywith black ink, thereby preparing a sample that allows no reflection atthe back surface of the glass plate. The sample is set in anellipsometer (VASE, manufactured by J. A. Woollam Japan), and therefractive index is measured at a wavelength of 500 nm and at anincidence angle of 50° to 80°. The mean value of the thus-obtainedmeasured values is set as the refractive index.

The thickness of the void-containing layer of the present invention isnot particularly limited, and the lower limit thereof is, for example,0.05 μm or more or 0.1 μm or more, and the upper limit thereof is, forexample, 1000 μm or less or 100 μm or less, and the range thereof is,for example, from 0.05 to 1000 μm or 0.1 to 100 μm.

The form of the void-containing layer of the present invention is notparticularly limited, and may be, for example, in the form of a film, ablock, or the like.

The method for producing the void-containing layer of the presentinvention is not particularly limited, and can be produced by, forexample, the method as will be described below.

3. Nanoparticles, Surfaces of which are Modified with a Compound Havinga Surface Orientation

The void-containing layer of the present invention includes a compoundhaving a surface orientation, as described above.

The compound having the surface orientation may contain, for example, afluoroalkyl group having 5 to 17 or 5 to 10 fluorine atoms. Thefluoroalkyl group may be an alkyl group in which only a part of hydrogenis substituted with fluorine, or may be an alkyl group (perfluoroalkylgroup) in which all hydrogen is substituted with fluorine. Thefluoroalkyl group may be, for example, a fluoroalkyl group including aperfluoroalkyl group in a part of its structure. The alkyl group in thefluoroalkyl group is not particularly limited, and, may be a straightchain or branched alkyl group having 2 to 10 carbon atoms, for example.

As described above, for example, the compound having the surfaceorientation is an alkoxysilane derivative, and the alkoxysilanederivative may contain a fluoroalkyl group having 5 to 17 or 5 to 10fluorine atoms. The fluoroalkyl group may be an alkyl group in whichonly a part of hydrogen is substituted with fluorine, or may be an alkylgroup (perfluoroalkyl group) in which all hydrogen is substituted withfluorine. The fluoroalkyl group may be, for example, a fluoroalkyl groupincluding a perfluoroalkyl group in a part of its structure. The alkylgroup in the fluoroalkyl group is not particularly limited, and, may bea straight chain or branched alkyl group having 2 to 10 carbon atoms,for example, as described above.

The alkoxysilane derivative may be, for example, a monoalkoxysilane adialkoxysilane, a trialkoxysilane, or a tetraalkoxysilane derivative.More specifically, the alkoxysilane derivative may be a derivative inwhich one or more alkyl groups among the alkoxy groups in one moleculeof the alkoxysilane is substituted with the fluoroalkyl group. The alkylgroup in the fluoroalkyl group is, for example, as described above. Inaddition, in the molecule of the alkoxysilane derivative, the alkoxygroup in which the alkyl group is not substituted with the fluoroalkylgroup is not particularly limited, and is, for example, a straight chainor branched alkyl group having 1 to 4 carbon atoms, and may be, forexample, a methoxy group or the like. Specific examples of thealkoxysilane derivative includetrimethoxy(1H,1H,2H,2H-nonafluorohexyl)silane,trimethoxy(1H,1H,2H,2H-heptadecafluorodecyl)silane, andtriethoxy[5,5,6,6,7,7,7-heptafluoro-4,4-bis(trifluoromethypheptl]silane.In addition, only one type of the alkoxysilane derivative may be usedalone or a plurality of types of them may be used in combination.

As an example of the compound having the surface orientation, besidesthe alkoxysilane derivative, for example, a surfactant having aperfluoro group and further having a hydrophilic site such as a hydroxylgroup or a sodium sulfonate group and a hydrophobic site in onestructure at a terminal thereof can be given.

The nanoparticle is not particularly limited, and may be, for example, asilica particle, and more specifically, for example, a pulverizedproduct of a silicon compound gel as described below, or the like. Theparticle diameter of the nanoparticle is not particularly limited, and,for example, the volume average particle diameter may be 1 nm or more, 2nm or more, 3 nm or more, or 5 nm or more, and 1000 nm or less, 500 nmor less, 200 nm or less, or 50 nm or less. The volume average particlediameter can be measured using a particle size distribution analyzerbased on dynamic light scattering, laser diffraction, or the like, orusing an electron microscope such as a scanning electron microscope(SEM) or a transmission electron microscope (TEM), for example.

The method of modifying the nanoparticles with the compound having thesurface orientation is not particularly limited, and, for example, aknown method or the like can be appropriately used. More specifically,for example, the nanoparticles and the compound having the sur faceorientation may be heated and reacted in a liquid. The medium(dispersion medium) in the liquid is not particularly limited, and maybe, for example, water and alcohol, and only one type of them may beused alone or a plurality of types of them may be used in combination.Examples of the alcohol include IPA (isopropyl alcohol), IBA (isobutylalcohol), ethanol, and methanol, and may include solvents other than theabove-described alcohols such as MIBK (methyl isobutyl ketone) and MEK(methyl ethyl ketone). The reaction temperature and the reaction time ofthe reaction are not particularly limited, and can be appropriately set.

4. Void-Containing Layer Production Method and Laminate ProductionMethod

The void-containing layer production method and laminate productionmethod of the present invention are not particularly limited, and can beperformed by, for example, the production method described below. Thefollowing description, however, is illustrative and does not limit theinvention in any way. In the following description, the void-containinglayer production method of the present invention may be referred to as a“void-containing layer production method of the present invention”.

4-1. Void-Containing Layer Production Method

The void-containing layer production method of the present invention isdescribed below with reference to examples. The void-containing layerproduction method of the present invention, however, is not limited inany way by the following description.

The void-containing layer of the present invention may be formed, forexample, of a silicon compound. Also, the void-containing layer of thepresent invention may be, for example, a void-containing layer formed bychemically bonding microporous particles. For example, the microporousparticles may be gel pulverized products. The void-containing layer mayinclude, in addition to a skeleton formed by chemical bonding betweenthe microporous particles, nanoparticles, surfaces of which are modifiedwith the compound having the surface orientation, for example.

In the void-containing layer production method of the present invention,for example, the gel pulverization step of pulverizing the porous gelmaterial may be performed by one stage, however, is preferably performedby multiple stages. The number of the pulverization stages is notlimited to particular numbers and may be, for example, two, three ormore.

In the present invention, the shape of the “particle” (e.g., theparticle of the gel pulverized product) is not limited to particularshapes and may be, for example, a spherical shape or non-sphericalshape. In the present invention, the particle of the gel pulverizedproduct may be, for example, a sol-gel beaded particle, a nanoparticle(hollow nanosilica/nanoballoon particle), or a nanofiber.

In the present invention, for example, the gel is preferably a porousgel, and the gel pulverized product is preferably a porous gelpulverized product. The present invention, however, is by no meanslimited thereto.

In the present invention, the gel pulverized product may be in at leastone form selected from particulate forms, fibrous forms, and plate-likeforms, for example. The particulate structural unit and the plate-likestructural unit may be made of an inorganic substance, for example. Theconstituent element(s) of the particulate structural units includes atleast one element selected from the group consisting of Si, Mg, Al, Ti,Zn, and Zr, for example. The particulate structure (structural unit) maybe a solid particle or a hollow particle, and specific examples thereofinclude silicone particles, silicone particles having micropores, silicahollow nanoparticles, and silica hollow nanoballoons. The fibrousstructural unit may be, for example, a nanofiber with a nano-sizeddiameter, and specific examples thereof include cellulose nanofibers andalumina nanofibers. The plate-like structural unit may be, for example,nanoclay, and specific examples thereof include nano-sized bentonite(e.g., Kunipia F (trade name)). The fibrous structural unit is notparticularly limited, and may be, for example, at least one fibroussubstance selected from the group consisting of car bon nanofibers,cellulose nanofibers, alumina nanofibers, chitin nanofibers, chitosannanofibers, polymer nanofibers, glass nanofibers, and silica nanofibers.

In the void-containing layer production method of the present invention,the gel pulverization step (e.g., multiple pulverization stagesincluding the first pulverization stage and the second pulverizationstage) may be performed in “another solvent”, for example. The “anothersolvent” is described in detail below.

In the present invention, the “solvent” (e.g., a gel production solvent,a void-containing layer production solvent, a replacement solvent) maynot dissolve a gel or pulverized products thereof, and the gel or thepulverized products thereof may be dispersed or precipitated in thesolvent.

The volume average particle diameter of the gel after the firstpulverization stage may be, for example, from 0.5 to 100 μm, from 1 to100 μm, from 1 to 50 μm, from 2 to 20 μm, or from 3 to 10 μm. The volumeaverage particle diameter of the gel after the second pulverizationstage may be, for example, from 10 to 1000 nm, from 100 to 500 mm, orfrom 200 to 300 nm. The volume average particle diameter indicates avariation in particle size of the pulverized products in the solutioncontaining the gel (gel-containing solution). The volume averageparticle diameter can be measured using a particle size distributionanalyzer based on dynamic light scattering, laser diffraction, or thelike, or using an electron microscope such as a scanning electronmicroscope (SEM) or a transmission electron microscope (IEM), forexample.

The void-containing layer production method of the present inventionfurther includes, for example, a step of gelling a massive porousmaterial in a solvent to obtain a gel. In this case, the gel obtained bythe gelation step may be used in the first pulverization stage (e.g.,the first pulverization stage) among the pulverization stages, forexample.

The void-containing layer production method of the present inventionfurther includes, for example, a step of aging the gel in a solvent. Inthis case, the gel after the aging step may be used in the firstpulverization stage (e.g., the first pulverization stage) among thepulverization stages, for example.

In the void-containing layer production method of the present invention,a step of replacing the solvent with “another solvent” is performedafter the gelation step, for example. In this case, the gel in “anothersolvent” may be used in the first pulverization stage (e.g., the firstpulverization stage) among the pulverization stages, for example.

For example, the pulverization of the porous material is controlledwhile measuring the shear viscosity of the solution in at least one ofthe pulverization stages (e.g., at least one of the first pulverizationstage and the second pulverization stage) in the void-containing layerproduction method of the present invention.

At least one of the pulverization stages (e.g., at least one of thefirst pulverization stage and the second pulverization stage) in thevoid-containing layer production method of the present invention isperformed by, for example, high pressure media-less pulverization.

In the void-containing layer production method of the present invention,the gel is, for example, a gel of a silicon compound at least containingthree or less functional groups having saturated bonds.

Hereinafter, in the void-containing layer production method of thepresent invention, the gel pulverized product-containing solutionobtained by the steps including the gel pulverization step may bereferred to as the “gel pulverized product-containing solution of thepresent invention”.

According to the gel pulverized product-containing solution of thepresent invention, for example, the void-containing layer of the presentinvention as a functional porous material can be formed by forming acoating film of the solution and chemically bonding the pulverizedproducts in the coating film. According to the gel pulverizedproduct-containing solution of the present invention, for example, thevoid-containing layer of the present invention can be applied to variousobjects. Therefore, the gel pulverized product-containing solution ofthe present invention and the production method of the same are useful,for example, in the production of the void-containing layer of thepresent invention.

Since the gel pulverized product-containing solution of the presentinvention has, for example, significantly excellent uniformity, forexample, when the void-containing layer of the present invention isapplied to an optical member, the appearance of the member can beimproved.

The gel pulverized product-containing solution may be, for example, agel pulverized product-containing solution for obtaining a layer(void-containing layer) having a high void fraction by applying(coating) the gel pulverized product-containing solution onto a base andthen drying the coated gel pulverized product-containing solution. Thegel pulverized product-containing solution of the present invention maybe, for example, a gel pulverized product-containing solution forobtaining a porous material (a bulk body having a large thickness or amassive bulk body) having a high void fraction. The bulk body can beobtained, for example, by performing bulk film formation using the gelpulverized product-containing solution.

For example, the void-containing layer of the present invention having ahigh void fraction can be produced by a production method including thesteps of producing the gel pulverized product-containing solution of thepresent invention, adding nanoparticles, surfaces of which are modifiedwith the compound having the surface orientation, to the gel pulverizedproduct-containing solution, coating the gel pulverizedproduct-containing solution onto a base to form a coating film, anddrying the coating film.

Further, for example, as shown in FIGS. 2 and 3, a laminated film in theform of a roll (laminated film roll) can be produced by a productionmethod including the steps of producing the gel pulverizedproduct-containing solution of the present invention, feeding the rolledresin film, coating the gel pulverized product-containing solution ontothe fed resin film to form a coating film, drying the coating film, and,after the drying step, winding up the laminated film in which thevoid-containing layer of the present invention is formed on the resinfilm.

4-2. Gel Pulverized Product-Containing Solution and Gel PulverizedProduct-Containing Solution Production Method

The gel pulverized product-containing solution of the present inventioncontains, for example, gel pulverized products pulverized by the gelpulverization step (e.g., the first pulverization stage and the secondpulverization stage) and the other solvent.

The void-containing layer production method of the present invention mayinclude, for example, as described above, multiple pulverization stagesof a gel pulverization step of pulverizing the gel (e.g., porous gelmaterial), which may include, for example, the first pulverization stageand the second pulverization stage. The present invention will bedescribed below with reference to examples in which the gel pulverizedproduct-containing solution production method of the present inventionincludes the first pulverization stage and the second pulverizationstage. The following description is made mainly for the case where thegel is a porous material (porous gel material). The present invention,however, is by no means limited thereto, and the description of the casewhere the gel is a porous material (porous gel material) can be appliedin an analogical manner to other cases. Hereinafter, the pulverizationstages (e.g., the first pulverization stage and the second pulverizationstage) in the void-containing layer production method of the presentinvention may be collectively also referred to as the “gel pulverizationstep”.

The gel pulverized product-containing solution of the present inventioncan be used in the production of a functional porous material thatexhibits the same function as an air layer (e.g., a refractive index) asdescribed below. The functional porous material may be, for example, thevoid-containing layer of the present invention. Specifically, the gelpulverized product-containing solution obtained by the production methodof the present invention contains pulverized products of the porous gelmaterial, the three-dimensional structure of the non-pulverized porousgel material in the pulverized products is destroyed, whereby a newthree-dimensional structure different from that of the non-pulverizedporous gel material can be formed in the pulverized products. Thus, forexample, a coating film (functional porous material precursor) formedusing the gel pulverized product-containing solution becomes a layerhaving a new pore structure (new void-containing structure) that cannotbe obtained in a layer formed using the non-pulverized porous gelmaterial. Thereby, the layer having a new pore structure can exhibit thesame function (have, for example, the same refractive index) as the airlayer. Further, for example, since pulverized products of the gelpulverized product-containing solution of the present invention haveresidual silanol groups, after forming a new three-dimensional structureas the coating film (functional porous material precursor), thepulverized products can be bonded chemically to each other. Thus, eventhough the functional porous material to be formed has a structure withvoid spaces, it can maintain a sufficient strength and sufficientflexibility. Therefore, according to the present invention, thefunctional porous material can be easily and simply applied to variousobjects. The gel pulverized product-containing solution obtained by theproduction method of the present invention is very useful, for example,in the production of the porous structure which can be a substitute foran air layer. In the case of funning an air layer, it is necessary tolaminate the components with a space therebetween by providing a spaceror the like to form an air layer between components, for example.However, the functional porous material formed by using the gelpulverized product-containing solution of the present invention canexhibit the same function as the air layer by simply disposing it on anintended site. Therefore, as described above, the present invention canallow various objects to exhibit the same function as that of an airlayer easily and simply as compared with the case of forming the airlayer.

The gel pulverized product-containing solution of the present inventionalso can be referred to as, for example, a solution for forming thefunctional porous material or a solution for forming a void-containinglayer or a low refractive index layer. In the gel pulverizedproduct-containing solution of the present invention, the porousmaterial is the pulverized product.

The range of the volume average particle diameter of the pulverizedproducts (particles of porous gel material) in the gel pulverizedproduct-containing solution of the present invention is, for example,from 10 to 1000 nm, from 100 to 500 nm, and from 200 to 300 nm. Thevolume average particle diameter indicates a variation in particle sizeof the pulverized products in the gel pulverized product-containingsolution according to the present invention. The volume average particlediameter can be measured using a particle size distribution analyzerbased on dynamic light scattering, laser diffraction, or the like, orusing an electron microscope such as a scanning electron microscope(SEM) or a transmission electron microscope (TEM), as described above,for example.

The concentration of the gel pulverized products in the gel pulverizedproduct-containing solution of the present invention is not limited toparticular concentrations and is, for example, from 2.5 to 4.5 wt %,from 2.7 to 4.0 wt %, or from 2.8 to 3.2 wt % as particles with aparticle diameter from 10 to 1000 nm.

The gel (e.g., porous gel material) in the gel pulverizedproduct-containing solution of the present invention is not limited toparticular gels and can be, for example, a silicon compound.

The silicon compound is not limited to particular compounds and, can be,for example, a silicon compound at least containing three or lessfunctional groups having saturated bonds. “Containing three or lessfunctional groups having saturated bonds” means that the siliconcompound contains three or less functional groups and these functionalgroups have saturated bonds with silicon (Si).

The silicon compound is, for example, a compound represented by thefollowing chemical formula (2).

In the chemical formula (2), for example, X is 2, 3, or 4, R¹ and R² areeach a linear or branched alkyl group, R¹ and R² may be the same ordifferent from each other, R¹ may be the same or different from eachother when X is 2, and R² may be the same or different from each other.

X and R¹ are the same as those in the chemical formula (1) to bedescribed below, for example. Regarding R², reference can be made to thedescription as to the examples of R¹ in the chemical formula (1), forexample.

A specific example of the silicon compound represented by the chemicalformula (2) is the one in which X is 3, which is a compound representedby the following chemical formula (2′). In the chemical formula (2′), R¹and R² are the same as those in the chemical formula (2). When R¹ and R²are both methyl groups, the silicon compound is trimethoxy(methyl)silane(also referred to as “MTMS” hereinafter).

In the gel pulverized product-containing solution of the presentinvention, the solvent can be, for example, a dispersion medium. Thedispersion medium (hereinafter, also referred to as “coating solvent”)is not limited to particular media and can be, for example, a gelationsolvent or a pulverization solvent and is preferably the pulverizationsolvent. The coating solvent contains an organic solvent having aboiling point of 70° C. or higher and less than 180° C. and a saturationvapor pressure of 15 kPa or less at 20° C.

Examples of the organic solvent include carbon tetrachloride,1,2-dichloroethane, 1,1,2,2-tetrachloroethane, trichloroethylene,isopropyl alcohol, isopropyl alcohol, isopentyl alcohol, 1-pentylalcohol (pentanol), ethyl alcohol (ethanol), ethylene glycol monoethylether, ethylene glycol monoethyl ether acetate, ethylene glycolmono-n-butyl ether, ethylene glycol monomethyl ether, xylene, cresol,chlorobenzene, isobutyl acetate, isopropyl acetate, isopentyl acetate,ethyl acetate, n-butyl acetate, n-propyl acetate, n-pentyl acetate,cyclohexanol, cyclohexanone, 1,4-dioxane, N,N-dimethylformamide,styrene, tetrachloroethylene, 1,1,1-trichloroethane, toluene, 1-butanol,2-butanol, methyl isobutyl ketone, methyl ethyl ketone, methylcyclohexanol, methyl cyclohexanone, methyl n-butyl ketone, andisopentanol. The dispersion medium may contain an appropriate amount ofa perfluoro-based surfactant or silicon-based surfactant that reducesthe surface tension.

The gel pulverized product-containing solution can be, for example, asol particle solution obtained by dispersing the pulverized products inthe dispersion medium. By coating the gel pulverized product-containingsolution of the present invention onto the base, drying the gelpulverized product-containing solution, and chemically crosslinking theparticles in the gel pulverized product-containing solution in thebonding step to be described below, for example, a void-containing layerhaving film strength at or above a certain level can be formedcontinuously. The term “sol” as used in the present invention refers toa state where, by pulverizing a three-dimensional structure of a gel,pulverized products (i.e., particles of porous sol material each havinga three-dimensional nanostructure holding part of the void-containingstructure) are dispersed in a solvent and exhibit fluidity.

A catalyst for chemically bonding the pulverized products of the gel toeach other can be added to the gel pulverized product-containingsolution of the present invention, for example. The content of thecatalyst is not limited to particular contents and is, for example, from0.01 to 20 wt %, from 0.05 to 10 wt %, or from 0.1 to 5 wt %, relativeto the weight of the gel pulverized products.

The gel pulverized product-containing solution of the present inventionmay contain a crosslinking assisting agent for indirectly bonding thepulverized products of the gel, for example. The content of thecrosslinking assisting agent is not limited to particular contents andis, for example, from 0.01 to 20 wt %, from 0.05 to 15 wt %, or from 0.1to 10 wt % with respect to the weight of the pulverized product of thegel.

The proportion of functional groups that are not involved in acrosslinked structure inside the gel among functional groups ofstructural unit monomers of the gel in the pulverized product-containingsolution of the present invention may be, for example, 30 mol % or less,25 mol % or less, 20 mol % or less, or 15 mol % or less, and may be, forexample, 1 mol % or more, 2 mol % or more, 3 mol % or more, or 4 mol %or more. The proportion of functional groups that are not involved inthe crosslinked structure inside the gel can be measured as follows, forexample.

(Measurement Method of Proportion of Functional Groups that are notInvolved in Crosslinked Structure Inside Gel)

The gel after drying is subjected to a solid state NMR (Si-NMR), and theproportion of residual silanol groups that are not involved in, acrosslinked structure (functional groups that are not involved in thecrosslinked structure inside the gel) is calculated from the peak ratioobtained by the NMR. Further, when the functional group is other thanthe silanol group, the proportion of functional groups that are notinvolved in a crosslinked structure inside the gel can be calculatedfrom the peak ratio obtained by the NMR according to this method.

The gel pulverized product-containing solution production method of thepresent invention will be described below with reference to examples.Regarding the gel pulverized product-containing solution of the presentinvention, reference can be made to the following description unlessotherwise stated.

A mixing step of mixing particles (pulverized products) of the porousgel material and the solvent is an optional step, and the gel pulverizedproduct-containing solution production method of the present inventionmay or may not include the mixing step. A specific example of the mixingstep includes, for example, a step of mixing a dispersion medium andpulverized products of a gelled silicon compound (silicon compound gel)obtained from a silicon compound at least containing three or lessfunctional groups having saturated bonds. In the present invention, thepulverized products of the porous gel material can be obtained from theporous gel material by the gel pulverization step to be described below,for example. The pulverized products of the porous gel material can beobtained from the porous gel material that is obtained after an agingtreatment in an aging step to be described below, for example.

In the gel pulverized product-containing solution production method ofthe present invention, the gelation step is, for example, a step ofgelling a massive porous material in a solvent to produce a porous gelmaterial. A specific example of the gelation step can be, for example, astep of gelling a silicon compound at least containing three or lessfunctional groups having saturated bonds in a solvent to generate asilicon compound gel.

The gelation step will be described below with reference to the casewhere the porous material is a silicon compound as an example.

The gelation step is, for example, a step of gelling the monomer siliconcompound by a dehydration condensation reaction in the presence of adehydration condensation catalyst, and by the gelation step, a siliconcompound gel is obtained. The silicon compound gel has, for example, aresidual silanol group, and the residual silanol group is preferablyadjusted, as appropriate, according to the chemical bonding amongpulverized products of the silicon compound gel to be described below.

In the gelation step, the silicon compound is only required to be gelledby a dehydration condensation reaction and is not limited to particularcompounds. For example, the silicon compounds are bonded by thedehydration condensation reaction. Bonding between the silicon compoundsis, for example, hydrogen bonding or intermolecular force bonding.

The silicon compound can be, for example, a silicon compound representedby the chemical formula (1). The silicon compound represented by thechemical formula (1) has hydroxyl groups. Thus, silicon compounds of thechemical formula (1) can be bonded to each other by hydrogen bonding orintermolecular bonding via their hydroxyl groups, for example.

In the chemical formula (1), X is 2, 3, or 4, and Fe is a linear or abranched alkyl group for example. The number of carbon atoms in R¹ is 1to 6, 1 to 4, or 1 to 2, for example. The linear alkyl group is a methylgroup, an ethyl group, a propyl group, a butyl group, a pentyl group, ora hexyl group, for example. The branched alkyl group is an isopropylgroup or an isobutyl group, for example. The X is 3 or 4, for example.

A specific example of the silicon compound represented by the chemicalformula (1) is the one in which X is 3, which is a compound representedby the following chemical formula (1′). In the chemical formula (1′), R¹is the same as that in the chemical formula (1), and is, for example, amethyl group. When R¹ is a methyl group, the silicon compound istris(hydroxy)methylsilane. When X is 3, the silicon compound is atrifunctional silane having three functional groups, for example.

Another specific example of the silicon compound represented by thechemical formula (1 is the one in Which X is 4. In this case, thesilicon compound is a tetrafunctional silane having four functionalgroups, for example.

The silicon compound may be a precursor for forming a silicon compoundrepresented by the chemical formula (1) by hydrolysis, for example. Theprecursor is not limited as long as it can generate the silicon compoundwhen it is hydrolyzed, for example. A specific example of the siliconcompound precursor is a compound represented by the chemical formula(2).

When the silicon Compound is a precursor represented by the chemicalformula (2), the production method of the present invention may furtherinclude the step of hydrolyzing the precursor prior to the gelationstep, for example.

The method for the hydrolysis of the precursor is not limited toparticular methods, and the precursor can be hydrolyzed through achemical reaction in the presence of a catalyst, for example. Examplesof the catalyst include acids such as an oxalic acid and an acetic acid.The hydrolysis reaction can be caused by, for example, adding, anaqueous oxalic acid solution dropwise slowly to a solution of thesilicon compound precursor in dimethylsulfoxide at room temperature andthen stilling the resultant mixture for about 30 minutes. In hydrolysisof the silicon compound precursor, for example, by hydrolyzing thealkoxy group of the silicon compound precursor completely, it ispossible to more efficiently achieve gelation and aging to be performedsubsequently and heating and immobilization to be performed after theformation of a void-containing structure.

In the present invention, the silicon compound can be, for example, ahydrolysate of trimethoxy(methyl)silane.

The monomer silicon compound is not limited to particular compounds andcan be selected, as appropriate, according to the intended use of thefunctional porous material to be produced, for example. In production ofthe functional porous material, the silicon compound preferably is thetrifunctional slime in terms of its excellent properties to achieve alow refractive index when a premium is placed on the low refractiveindex, for example. The silicon compound preferably is thetetrafunctional silane from the viewpoint of imparting high abrasionresistance when a premium is placed on strength (e.g., abrasionresistance), for example. As the silicon compound as a raw material ofthe silicon compound gel, only one type of silicon compound may be used,or two or more types of silicon compounds may be used in combination,for example. Specifically, the silicon compound may be made up of thebifunctional silane only, the tetrafunctional silane only, or both thebifunctional silane and the tetrafunctional silane, for example. Also,the silicon compounds may further include a silicon compound(s) otherthan the trifunctional slime and the tetrafunctional silane, forexample. When two or more types of silicon compounds are used as thesilicon compounds, the ratio thereof is not limited to particularsratios and can be set as appropriate.

The gelation of porous material such as the silicon compound on beachieved by a dehydration condensation reaction of the porous bodies,for example. The dehydration condensation reaction preferably isperformed in the presence of a catalyst, for example. Examples of thecatalyst include dehydration condensation catalysts such acid catalystsincluding a hydrochloric acid, an oxalic acid, and a sulfinic acid; andbase catalysts including ammonia, potassium hydroxide, sodium hydroxide,and ammonium hydroxide. The dehydration condensation catalystparticularly preferably is a base catalyst. In the dehydrationcondensation reaction, the amount of the catalyst to be added relativeto the porous material is not limited to particular materials, and is,for example, from 0.01 to 10 mol, from 0.05 to 7 mol or from 0.1 to 5mol per mole of the porous material.

The gelation of the porous material such as the silicon compoundpreferably is performed in a solvent, for example. The proportion of theporous material in the solvent is not limited to particular proportions.Examples of the solvent include dimethylsulfoxide (DMSO),N-methylpyrrolidone (NMP), N,N-dimethylacetamide (DMAc),dimethylformamide (DMF), γ-butyrolactone (GBL), acetonitrile (MeCN), andethylene glycol ethyl ether (EGEE). One type of solvent may be used, ortwo or more types of solvents may be used in combination, for example.Hereinafter, the solvent used for the gelation also is referred to as a“gelation solvent”.

The conditions for the gelation are not limited to particularconditions. The treatment temperature for treating the solventcontaining the porous material is, for example, from 20° C. to 30° C.,from 22° C. to 28° C., or from 24° C. to 26° C., and the treatment timefor treating the same is, for example, from 1 to 60 minutes, from 5 to40 minutes, or from 10 to 30 minutes. When the dehydration condensationreaction is performed the treatment conditions are not limited toparticular conditions, and the treatment conditions given above asexamples also apply to the dehydration condensation reaction. When theporous material is a silicon compound, siloxane bonds are gown andsilica primary particles are formed by the gelation, for example. As thereaction further proceeds, the primary particles are connected in theform of a string of beads, whereby a gel having a three-dimensionalstructure is generated.

The form of the gel obtained from the porous material in the gelationstep is not limited to particular forms. The term “gel” generally refersto a solidified state of a solute where particles of the solute havelost their independent mobility owing to interaction and form anaggregate. Among various types of gels, a “wet gel” generally refers toa gel containing a dispersion medium in which particles of a solutebuild a uniform structure, and a “xerogel” generally refers to a gelfrom Which a solvent is removed and in which particles of a solute forma network structure with void spaces. In the present invention, forexample, a wet gel is preferably used as the silicon compound gel. Whenthe porous gel material is a silicon compound gel, the amount of aresidual silanol group in the silicon compound gel is not limited toparticular amounts and can be, for example, in the same range to bedescribed below.

The porous gel material per se obtained by the gelation May be subjectedto the solvent replacement step and the first pulverization stage or maybe subjected to an aging treatment in the aging step prior to the firstpulverization stage, for example. In the suing step, the gelled porousmaterial (porous gel material) is aged in a solvent. The conditions forthe aging treatment in the aging step are not limited to particularconditions, and for example, the porous gel material may be incubated ina solvent at a predetermined temperature. For example, by furthergrowing the primary particles of the porous gel material having athree-dimensional structure obtained by the gelation through the agingtreatment, it is possible to increase the size of the particlesthemselves. As a result, the contact area at the neck portion where theparticles are in contact with each other increases so that the contactstate can be changed from point contact to surface contact. Theabove-described aging treatment of the porous gel material improves thestrength of the gel itself, for example, whereby the strength of thethree-dimensional basic structures of the pulverized products afterpulverization can be improved. As a result, it is possible to reduce thepossibility that, in the drying step to be performed after coating abase with the gel pulverized product-containing solution according tothe present invention to form a coating film, pores in thevoid-containing structure formed by deposition of the three-dimensionalbasic structures may become smaller as the solvent in the coating filmvolatilizes during the drying step, for example.

As to the temperature for the aging treatment, the lower limit thereofis, for example, 30° C. or higher, 35° C. or higher, or 40° C. orhigher. The upper limit thereof is, for example, 80° C. or lower, 75° C.or lower, or 70° C. or lower. The range thereof is, for example, from30° C. to 80° C., from 35° C. to 75° C., or from 40° C. to 70° C. Thepredetermined time is not limited to particular times. The lower limitthereof is, for example, 5 hours or more, 10 hours or more, or 15 hoursor more. The upper limit thereof is, for example, 50 hours or less, 40hours or less, or 30 hours or less. The range thereof is, for example,from 5 to 50 hours, from 10 to 40 hours, or from 15 to 30 hours. Optimalaging conditions are, for example, as described above, conditions set toincrease the size of the primary particles and to increase the contactarea at the neck portion in the porous gel material. Furthermore, it ispreferable to take the boiling point of the solvent used intoconsideration for the temperature in the aging treatment in the agingstep, for example. For example, when the aging temperature is too highin the aging treatment, the solvent may volatilize excessively to causedefectiveness such that the pores in the three-dimensionalvoid-containing structure are closed due to the condensation of theconcentration of the coating solution. On the other hand, for example,when the aging temperature is too low in the aging treatment, the effectof the aging cannot be obtained sufficiently Besides, variation intemperature over time in a mass production process increases, which mayresult in products with poor quality.

In the aging treatment, the same solvent as in the gelation step can beused, for example. Specifically, it is preferable that a reactantobtained after the gelation treatment (i.e., the solvent containing theporous gel material) is subjected to the aging treatment as it is. Whenthe porous gel material is the silicon compound gel, the amount ofresidual silanol groups contained in the silicon compound gel havingbeen subjected to the gelation and the subsequent aging treatment bymole indicates, for example, the proportion of the residual silanolgroups, assuming that the amount of the alkoxy groups in the rawmaterial used in the gelation (e.g., the silicon compound or theprecursor thereof) b mole is 100. The lower limit thereof is, forexample, 50% or more, 40% or more, or 30% or more. The upper limitthereof is, for example, 1% or less, 3% or less, or 5% or less. Therange thereof is, for example, from 1% to 50%, from 3% to 40%, or from5% to 30%. For the purpose of increasing the hardness of the siliconcompound gel, it is preferable that the amount of the residual silanolgroups by mole is smaller, for example. When the amount of the silanolgroups by mole is too large, there is a possibility that thevoid-containing structure cannot be maintained until the crosslinking ofthe functional porous material precursor is completed in formation ofthe functional porous material, for example. On the other hand, when thenumber of moles of the silanol groups is too small, there is apossibility that, in the bonding step, the functional porous materialprecursor cannot be crosslinked, so that a sufficient film strengthcannot be imparted, for example. The above description is directed to anexample where residual silanol groups are used. When the siliconcompounds that have been modified with various reactive functionalgroups are used as raw materials of the silicon compound gel, forexample, the same phenomenon can be applied to each of the reactivefunctional groups.

The porous gel material per se obtained by the gelation is subjected to,for example, an aging treatment in the aging step, then a solventreplacement step, and thereafter the gel pulverization step. In thesolvent replacement step, the solvent is replaced with another solvent.

In the present invention, the gel pulverization step is, as describedabove, a step of pulverizing the porous gel material. The porous gelmaterial after the gelation step may be subjected to the pulverization,and the porous gel material having been subjected to the aging treatmentmay further be subjected to the pulverization, for example.

Furthermore, as described above, the gel form control step ofcontrolling the shape and the size of the gel may be performed prior tothe solvent replacement step (e.g., after the aging step). The shape andthe size of the gel to be controlled in the gel form control step is notlimited to particular shapes and sizes and are, for example, asdescribed above. The gel form control step may be performed by dividingthe gel into solids (3D solid) in an appropriate size and shape, forexample.

Moreover, as described above, the gel pulverization step is performedafter subjecting the gel to the solvent replacement step. In the solventreplacement step, the solvent is replaced with another solvent. When thesolvent is not replaced with another solvent, the following problem mayarise. For example, the catalyst and solvent used in the gelation stepremain after the aging step to cause gelation of the solution over timeand affect the pot life of the gel pulverized product-containingsolution to be obtained finally, and the drying efficiency at the timewhen the coating film formed using the gel pulverized product-containingsolution is dried is reduced. Hereinafter, such a solvent in the gelpulverization step is also referred to as a “pulverization solvent”.

The pulverization solvent (another solvent) is not limited to particularsolvents, and may be, for example, an organic solvent. The organicsolvent may be, for example, the one having a boiling point of 140° C.or lower, 130° C. or lower, 100° C. or lower, or 85° C. or lower.Specific examples thereof include isopropyl alcohol (IPA), ethanol,methanol, butanol, n-butanol, 2-butanol, isobutyl alcohol, pentylalcohol, propylene glycol monomethyl ether (PGME), methyl cellosolve andacetone. One type of pulverization solvent may be used, or two or moretypes of pulverization solvents may be used in combination, for example.

When the pulverization solvent has a low polarity, for example, thesolvent replacement step is performed by multiple solvent replacementstages, and in the solvent replacement stages, the hydrophilicity ofsuch a solvent may be caused to be lower in a subsequent stage than thatin a prior stage. As a result, for example, solvent replacementefficiency can be improved, and the residual amount of a gel productionsolvent in the gel (e.g., DMSO) can be significantly reduced.Specifically, for example, the solvent replacement step is performed bythree solvent replacement stages, and DMSO in a gel may be firstreplaced with water in the first solvent replacement stage, the water inthe gel may then be replaced with IPA in the second solvent replacementstage, and the IPA in the gel may thereafter be replaced with isobutylalcohol in the third solvent replacement stage.

The combination of the gelation solvent and the pulverization solvent isnot limited to particular combinations, and examples thereof include thecombinations of: DMSO and IPA; DMSO and ethanol; DMSO and isobutylalcohol; and DMSO and n-butanol. By replacing the gelation solvent bythe pulverization solvent as described above, it is possible to form amore uniform coating film in the formation of the coating film to bedescribed below, for example.

The solvent replacement step is not limited to particular steps and canbe performed as follows, for example. That is, first, the gel (e.g., gelafter the aging treatment) produced in the gel production step isimmersed in or brought into contact with another solvent to dissolve agel production catalyst in the gel and an alcohol component and watergenerated by the condensation reaction in the solvent. The solvent inwhich the gel is immersed or with which the gel is brought into contactis drained, and the gel is again immersed or brought into contact with anew solvent. This is repeatedly performed until the residual amount ofthe gel production solvent in the gel becomes a desired amount. Eachimmersion time is, for example, 0.5 hours or more, 1 hour or more, or1.5 hours or more. The upper limit thereof is not limited to particulartimes and is, for example, 10 hours or less. The immersion in thesolvent may be performed by continuous contact of the solvent with thegel. The temperature during the immersion is not limited to particulartemperatures and is, for example, from 20° C. to 70° C., from 25° C. to65° C., or from 30° C. to 60° C. By heating, the solvent is replacedpromptly, and the amount of the solvent required for replacement can bereduced. However, the solvent may be simply replaced at roomtemperature. Further, for example, when the solvent replacement step isperformed by multiple solvent replacement stages, each of the solventreplacement stages may be performed in the manner described above.

When the solvent replacement step is performed by multiple solventreplacement stages, and the hydrophilicity of “another solvent” iscaused to be lower in a subsequent stage than that in a prior stage,such a solvent (replacement solvent) is not particularly limited. In thelast solvent replacement stage, it is preferable that “another solvent”(replacement solvent) is a void-containing layer production solvent.Examples of the void-containing layer production solvent include asolvent having a boiling point of 140° C. or lower. Examples of thevoid-containing layer production solvent include alcohol, ether, ketone,an ester solvent, an aliphatic hydrocarbon solvent, and an aromaticsolvent. Specific examples of the alcohol having a boiling point of 140°C. or lower include isopropyl alcohol (IPA), ethanol, methanol,n-butanol, 2-butanol, isobutyl alcohol (IBA), 1-pentanol, and2-pentanol. Specific examples of the ether having a boiling point of140° C. or lower include propylene glycol monomethyl ether (PGME),methyl cellosolve, and ethyl cellosolve. Specific examples of the ketonehaving a boiling point of 140° C. or lower include acetone, methyl ethylketone, methyl isobutyl ketone, and cyclopentanone. Specific examples ofthe ester solvent having a boiling point of 140° C. or lower includeethyl acetate, butyl acetate, isopropyl acetate, and normal propylacetate. Specific examples of the aliphatic hydrocarbon solvent having aboiling point of 140° C. or lower include hexane, cyclohexane, heptane,and octane. Specific examples of the aromatic solvent having a boilingpoint of 140° C. or lower include toluene, benzene, xylene, and anisole.From the viewpoint of hardly eroding the base (e.g., resin film) duringcoating, the void-containing layer production solvent is preferablyalcohol, ether, or an aliphatic hydrocarbon solvent. One type ofpulverization solvent may be used, or two or more types of pulverizationsolvents may be used in combination. In particular, from the viewpointof low volatility at room temperature, isopropyl alcohol (IPA), ethanol,n-butanol, 2-butanol, isobutyl alcohol (IBA), pentyl alcohol, propyleneglycol monomethyl ether (PGME), methyl cellosolve, heptane, and octaneare preferred. In particular, in order to prevent gel material particles(e.g., silica compounds) from scattering, it is preferable that thesaturation vapor pressure (volatility) of the void-containing layerproduction solvent be not too high. As such a solvent, for example, theone containing an aliphatic group having three or four or more carbonatoms is preferable, and the one containing an aliphatic group havingfour or more carbon atoms is more preferable. The solvent containing analiphatic group having three or four or more carbon atoms may be, forexample, alcohol. Specifically, for such a solvent, isopropyl alcohol(IPA), isobutyl alcohol (IBA), n-butanol, 2-butanol, 1-pentanol, and2-pentanol are preferable and isobutyl alcohol (IBA) is particularlypreferable.

Another solvent (replacement solvent) in a stage other than the lastsolvent replacement stage is not particularly limited, and examplesthereof include alcohol, ether, and ketone. Specific examples of alcoholinclude isopropyl alcohol (IPA), ethanol, methanol, n-butanol,2-butanol, isobutyl alcohol (IBA), and pentyl alcohol. Specific examplesof ether include propylene glycol monomethyl ether (PGME), methylcellosolve, and ethyl cellosolve. A specific example of ketone isacetone. Another solvent (replacement solvent) is not limited as long asit can replace the gel production solvent or “another solvent”(replacement solvent) in a previous stage. Also, another (replacementsolvent) in a stage other than the last solvent replacement stage ispreferably a solvent which does not finally remain in the gel or whichhardly erodes the base (e.g., resin film) during coating even if itremains in the gel. From the viewpoint of hardly eroding the base (e.g.,resin film) during coating, “another solvent” (replacement solvent) in astage other than the last solvent replacement stage is preferablyalcohol. Thus, in at least one of the multiple solvent replacementstages, “another solvent” is preferably alcohol.

In the first solvent replacement stage, “another solvent” may be, forexample, water or a mixed solvent containing water in freely-selectedproportion. Water or a mixed solvent containing water is highlycompatible with a gel production solvent (e.g., DMSO) having a highhydrophilicity, so that the gel production solvent can be easilyreplaced and is preferable in terms of costs.

The multiple solvent replacement stages may include a stage in which“another solvent” is water, then a stage in which “another solvent” isthe one containing an aliphatic group having three or less carbon atoms,and thereafter a stage in which “another solvent” is the one containingan aliphatic group having four or more carbon atoms. At least one of thesolvent containing an aliphatic group having three or less carbon atomsand the solvent containing an aliphatic group having four or more carbonatoms may be an alcohol. The alcohol having an aliphatic group havingthree or less carbon atoms is not particularly limited, and examplesthereof include isopropyl alcohol (IPA), ethanol, methanol, and n-propylalcohol. The alcohol having an aliphatic group having four or morecarbon atoms is not particularly limited, and examples thereof includen-butanol, 2-butanol isobutyl alcohol (IBA), and pentyl alcohol. Forexample, the solvent containing an aliphatic group having three or lesscarbon atoms may be isopropyl alcohol, and the solvent containing analiphatic group having four or more carbon atoms may be isobutylalcohol.

The inventors of the present invention have found that it is veryimportant to focus on the residual amount of the gel production solventin order to form a void-containing layer having film strength under arelatively mild condition such as at 200° C. or lower, for example. Thisfinding, which has been found independently by the inventors of thepresent invention, is not described in the prior arts including thepatent literature and the non-patent literature.

Although the reason (mechanism) why a void-containing layer having a lowrefractive index can be produced by reducing the residual amount of thegel production solvent in the gel is not necessarily clear, it isspeculated as follows, for example. That is, as described above, the gelproduction solvent is preferably a high-boiling-point solvent (e.g.,DMSO) or the like for the progress of gelation reactions. In productionof a void-containing layer by coating and drying a sol solution producedfrom the gel, it is difficult to completely remove thehigh-boiling-point solvent at a normal drying temperature and dryingtime (for example, 1 minute at 100° C., although it is not particularlylimited thereto). This is because if the drying temperature is too highor the (drying time is too long, problems such as deterioration of thebase may arise. In addition, it is speculated that thehigh-boiling-point solvent remaining at the time of coating and dryingenters between the gel pulverized products and slips the pulverizedproducts, whereby the pulverized products are densely deposited. Thismay decrease the void fraction, so that low refractive index is hardlyachieved. That is, conversely, it is speculated that such a phenomenoncan be prevented, and low refractive index can be achieved by reducingthe residual amount of the high-boiling-point solvent. It is to benoted, however, that the above-described reasons (mechanisms) merely areexamples based on the speculation and do not limit the present inventionby any means.

In the present invention, the “solvent” (e.g., a gel production solvent,a void-containing layer production solvent, a replacement solvent) maynot dissolve a gel or pulverized products thereof, and the gel or thepulverized products thereof may be dispersed or precipitated in thesolvent.

As described above, the gel production solvent may have a boiling pointof 140° C. or higher, for example.

The gel production solvent is, for example, a water-soluble solvent. Inthe present invention, the “water-soluble solvent” refers to a solventthat can be mixed with water in a freely-selected ratio.

When the solvent replacement step is performed by multiple solventreplacement stages, the method is not particularly limited, and each ofthe solvent replacement stages can be performed, for example, asfollows. That is, first, the gel is immersed in or brought into contactwith “another solvent” to dissolve a gel production catalyst in the gel,an alcohol component generated by the condensation reaction, and waterin “another solvent”. Thereafter, the solvent in which the gel has beenimmersed or with which the gel has been brought into contact is drained,and the gel is again immersed or brought into contact with a newsolvent. This is repeatedly performed until the residual amount of thegel production solvent in the gel becomes a desired amount. Eachimmersion time is, for example, 0.5 hours or more, 1 hour or more, or1.5 hours or more. The upper limit thereof is not limited to particulartimes and is, for example, 10 hours or less. The immersion in thesolvent may be performed by continuous contact of the solvent with thegel. The temperature during the immersion is not limited to particulartemperatures and is, for example, from 20° C. to 70° C., from 25° C. to65° C., or from 30° C. to 60° C. By heating, the solvent is replacedpromptly, and the amount of the solvent required for replacement can bereduced. However, the solvent may be simply replaced at roomtemperature. This solvent replacement stage is performed a plurality oftimes by gradually changing “another solvent” (replacement solvent) fromthe one having a high hydrophilicity to the one having a lowhydrophilicity (a high hydrophobicity). In order to remove a highlyhydrophilic gel production solvent (e.g., DMSO), for example, it issimple and efficient to first use water as a replacement solvent, asdescribed above. After removing the DMSO or the like with water, thewater in the gel is replaced with isopropyl alcohol and then withisobutyl alcohol (coating solvent) M this order, for example. That is,since water and isobutyl alcohol have low compatibility, the solventreplacement can be efficiently performed by once replacing withisopropyl alcohol and then with isobutyl alcohol, which is a coatingsolvent. However, this is an example, and, as described above, “anothersolvent” (replacement solvent) is not particularly limited.

In the gel production method of the present invention, for example, asdescribed above, the solvent replacement stage may be performed aplurality of times by gradually changing “another solvent” (replacementsolvent) from the one having a high hydrophilicity to the one having alow hydrophilicity (having a high hydrophobicity). This cansignificantly reduce the residual amount of the gel production solventin the gel as described above. In addition, for example, it is possibleto significantly reduce the amount of the solvent to be used and toreduce the cost, as compared with a case of performing the solventreplacement by one stage using only the coating solvent.

Moreover, after the solvent replacement step, the gel pulverization stepof pulverizing the gel in the pulverization solvent is performed.Furthermore, for example, as described above, the concentration of thegel may be performed, if necessary, after the solvent replacement stepand prior to the gel pulverization step, and the concentrationadjustment step may be performed thereafter if necessary. Theconcentration of the gel after the solvent replacement step and prior tothe gel pulverization step can be measured as follows, for example. Thatis, first, a gel is taken out from “another solvent” (pulverizationsolvent) after the solvent replacement step. This gel is controlled tobe masses in appropriate shapes and sizes (e.g., blocks) by the gel formcontrol step, for example. A solvent adhered to the periphery of eachmass of the gel is then removed, and the concentration of the solidcontent in one mass of the gel is measured by weight dry method. At thattime, the concentration of the solid content in each of a plurality ofrandomly sampled masses (e.g., 6 masses) is measured, and variations ofthe measured concentrations from the average thereof are calculated, todetermine reproducibility of the measured concentrations. In theconcentration adjustment step, for example, the concentration of the gelin the gel-containing solution may be decreased by adding “anothersolvent” (pulverization solvent). Alternatively, in the concentrationadjustment step, for example, the concentration of the gel in thegel-containing solution may be increased by evaporating “anothersolvent” (pulverization solvent).

In the gel pulverized product-containing solution production method ofthe present invention, for example, as described above, the gelpulverization step may be performed by one stage but is preferablyperformed by multiple stages, Specifically, for example, the firstpulverization. Stage and the second pulverization stage may beperformed. In addition to the first pulverization stage and the secondpulverization stage, a further pulverization stage may be performed asthe gel pulverization step. That is, in the gel pulverizedproduct-containing solution production method of the present invention,the number of pulverization stages included in the pulverization step isnot limited to two and may be three or more.

In the manner as described above, a solution (e.g., a suspension)containing the microporous particles (pulverized products of a gelledcompound) can be produced. By further adding a catalyst for chemicallybonding the microporous particles after or during the preparation of thesolution containing the microporous particles, it is possible to preparea solution containing the microporous particles and the catalyst. Theamount of the catalyst to be added is not particularly limited, and is,for example 0.01 to 20 wt %, 0.05 to 10 wt %, or 0.1 to 5 wt % relativeto relative to the weight of the pulverized products of the siliconcompound. The catalyst may be, for example, a catalyst that promotescrosslinking of the microporous particles. The chemical reaction forchemically bonding the microporous particles to each other preferably isa reaction utilizing a dehydration condensation reaction of residualsilanol groups contained in silica sol molecules. By promoting thereaction between the hydroxyl groups in the silanol groups by thecatalyst, the void-containing structure can be cured in a short time, sothat continuous film formation becomes possible. The catalyst may be aphotoactive catalyst or a thermoactive catalyst, for example. With theuse of the photoactive catalyst, in the void-containing layer formingstep, the microporous particles can be bonded (e.g., crosslinked) toeach other without heating, for example. Accordingly, the shrinkage ofthe entire void-containing layer is less liable to occur in thevoid-containing layer forming step, so that it is possible to maintain ahigher void fraction, for example. In addition to or instead of thecatalyst, a substance that generates a catalyst (catalyst generator) maybe used. For example, in addition to or instead of the photoactivecatalyst, a substance that generates a catalyst when subjected to lightirradiation (photocatalyst generator) may be used, and in addition to orinstead of the thermoactive catalyst, a substance that generates acatalyst when heated (thermal catalyst generator) may be used. Thephotocatalyst generator is not particularly limited, and may be, forexample, a photobase generator a substance that generates a basiccatalyst when subjected to light irradiation) or a photoacid generator(a substance that generates an acidic catalyst when subjected to lightirradiation). Among them, the photobase generator is preferable.Examples of the photobase generator include 9-anthrylmethylN,N-diethylcarbamate (trade name: WPBG-018),(E)-1-[3-(2-hydroxyphenyl)-2-propenoyl]piperidine (trade name:WPBG-027), 1-(anthraquinon-2-yl)ethyl imidazolecarboxylate (trade name:WPBG-140), 2-nitrophenylmethyl 4-methacryloyloxypiperidine-1-carboxylate(trade name: WPBG-165), 1,2-diisopropyl-3-[bis(dimethylamino)methylene]guanidium 2-(3-benzoylphenyl)propionate (trade name:WPBG-266), 1,2-dicyclohexyl-4,4,5,5-tetramethylbiguanidiumn-butyltriphenylborate (trade name: WPBG-300),2-(9-oxoxanthen-2-yl)propionic acid 1,5,7-triazabicyclo[4.4.0]dec-5-ene(Tokyo Kasei Kogyo Co., Ltd.), and a compound containing4-piperidinemethanol (trade name: HDPD-PB100, manufactured by Heraeus).Note here that the above products with the trade names including “WPBG”are all manufactured by Wako Pure Chemical Industries, Ltd. Examples ofthe photoacid generator include aromatic sulfonium salt (trade name:SP-170, manufactured by ADEKA), triarylsulfonium salt (trade name:CPI101A, manufactured by San-Apro Ltd.), and aromatic iodonium salt(trade name: Irgacure 250, manufactured by Ciba Japan). The catalyst forchemically bonding the microporous particles to each other is notlimited to the photoactive catalyst and the photocatalyst generator, andmay be a thermoactive catalyst or a thermal catalyst generator, forexample. Examples of the catalyst for chemically bonding the microporousparticles to each other include: base catalysts such as potassiumhydroxide, sodium hydroxide, and ammonium hydroxide and acid catalystssuch as a hydrochloric acid, an acetic acid, and an oxalic acid. Amongthem, the base catalysts are preferable. The catalyst or the catalystgenerator for chemically bonding the microporous particles to each othercan be used by adding it to a sol particle solution (e.g., suspension)containing the pulverized products (microporous particles) immediatelybefore coating the sol particle solution, or can be used in the form ofa mixture with a solvent, for example. The mixture may be, for example,a coating solution obtained by adding the catalyst directly to anddissolving the catalyst in the sol particle solution, a solutionobtained by dissolving the catalyst or the catalyst generator in asolvent, or a dispersion obtained by dispersing the catalyst or thecatalyst generator in a solvent. The solvent is not particularlylimited, and examples thereof include various organic solvents, water,and buffer solutions.

Furthermore, for example, after the solution containing the microporousparticles is produced, by adding a small amount of a high-boiling-pointsolvent to the solution containing the microporous particles, theappearance of the film in film formation by coating can be improved. Theamount of the high-boiling-point solvent is not particularly limited,and is, for example, 0.05 to 0.8 times, 0.1 to 0.5 times, andparticularly 0.15 to 0.4 times relative to the solid content of thesolution containing the microporous particles. The high-boiling-pointsolvent is not particularly limited and examples thereof includedimethyl sulfoxide (DMSO), N,N-dimethylformamide (DMF),N,N-dimethylacetamide (DMAc), N-methylpyrrolidone (NMP), γ-butyl lactone(GBL), and ethylene glycol ethyl ether (EGEE). In particular, a solventhaving a boiling point of 110° C. or higher is preferable, and thepresent invention is not limited to the specific examples describedabove. It is considered that the high-boiling-point solvent serves as aleveling agent in film forming in which particles are aligned. It ispreferable to use the above-described high-boiling-point solvent also inthe gel synthesis. It is to be noted, although details are unknown, thehigh-boiling-point solvent effectively acts when the high-boiling-pointsolvent is newly added to the solution containing the microporousparticles produced after the solvent used in the synthesis has beencompletely removed. It is to be noted, however, that the above-describedmechanisms merely are examples and do not limit the present invention byany means.

Then, nanoparticles, surfaces of which are modified with the compoundhaving the surface orientation, are added to the produced gel pulverizedproduct-containing solution, and the resultant gel pulverizedproduct-containing solution can be used for producing thevoid-containing layer of the present invention. At this time, forexample, as described above, the nanoparticles may be added at aproportion of, for example, 10 to 50 mass %, 15 to 40 mass %, or 20 to30 mass % relative to a skeleton component of the void-containing layer.

4-3. Void-Containing Layer Production Method, Laminate ProductionMethod, and Pressure-Sensitive Adhesive/Adhesive Layer Production Method

The laminate production method of the present invention is describedtogether with the methods of producing the void-containing layer andpressure-sensitive adhesive/adhesive layer that configure the laminate,with reference to examples. The methods will be described below mainlywith reference to a case in which the void-containing layer of thepresent invention is a silicone porous material formed of a siliconcompound. The void-containing layer of the present invention, however,is not limited only to a silicone porous material. Regarding the case inwhich the void-containing layer is other than a silicone-porousmaterial, reference can be made to the following description unlessotherwise stated. Further, in the following description, the gelpulverized product-containing solution used for producing thevoid-containing layer of the present invention contains nanoparticles,surfaces of which are modified with the compound having the surfaceorientation, unless otherwise specified. As described above, thenanoparticles, surfaces of which are modified with the compound having,the surface orientation, can be added to the gel pulverizedproduct-containing solution after being produced, for example.

The void-containing layer production method of the present inventionincludes, for example, the steps of forming a void-containing layerprecursor using the gel pulverized product-containing solution of thepresent invention, and chemically bonding the pulverized products of thegel pulverized product-containing solution contained in the precursor.The precursor may be referred to as a coating film, for example.

According to the void-containing layer production method of the presentinvention, for example, a porous structure having the same function asan air layer is formed. The reason for this is speculated as follows,for example. The present invention, however, is not limited by thisspeculation. The reason will be described below with reference to a casein which the void-containing layer is a silicone porous material.

The gel pulverized product-containing solution used in the method forproducing the silicone porous material contains pulverized products ofthe silicon compound gel. Thus, the three-dimensional structure of thegelled silica compound is dispersed in three-dimensional basicstructures of the pulverized products. Thus, in the method for producingthe silicone porous material, when the precursor (e.g., coating film) isformed using the gel pulverized product-containing solution, thethree-dimensional basic structures are deposited, and thevoid-containing structure based on the three-dimensional basicstructures are formed, for example. That is, according to the method forproducing a silicone porous material, a new porous structure differentfrom that of the silicon compound gel is formed of the pulverizedproducts having the three-dimensional basic structures. Moreover, in themethod for producing a silicone porous material, the pulverized productsare further chemically bonded to each other, whereby the newthree-dimensional structure is immobilized. Thus, even though thesilicone porous material to be obtained by the method for producing thesilicone porous material has a structure with void spaces, it canmaintain a sufficient strength and sufficient flexibility. Thevoid-containing layer (e.g., silicone porous material) obtained by thepresent invention can be used as a member utilizing voids in a widerange of products such as heat insulating materials, sound absorbingmaterials, optical members, ink-receiving layers, and the like, forexample. Furthermore, a laminated film having various functions impartedtherein can be produced using the void-containing layer.

Regarding the void-containing layer production method of the presentinvention, reference can be made to the description as to the gelpulverized product-containing solution of the present invention unlessotherwise stated.

In the precursor forming step of forming a porous material precursor,the gel pulverized product-containing, solution of the present inventionis coated on the base, for example. By coating the gel pulverizedproduct-containing solution of the present invention onto, for example,a base, diving the coating film, and thereafter chemically bonding(e.g., crosslinking) pulverized products in the bonding step, forexample, a void-containing layer having a film strength at or above acertain level can be formed continuously.

The amount of the gel pulverized product-containing solution to becoated onto the base is not particularly limited, and can be set asappropriate depending on, for example, a desired thickness of thevoid-containing layer of the present invention. As a specific example,when the silicone porous material having a thickness from 0.1 μm to 1000μm is to be formed, the amount of the pulverized products to be coatedonto the base is, for example, in the range from 0.01 to 60000 μg, 0.1to 5000 μg, or 1 to 50 μg per square meter of the base. It is difficultto uniquely define a preferable amount of the gel pulverizedproduct-containing solution to be coated, because it may be affected bythe concentration of the solution, the coating method, etc., forexample. However, in terms of productivity, it is preferable to make acoating layer as thin as possible. When the coating amount is too large,for example, it is likely that the solvent may be dried in a drying ovenbefore it volatilizes. If the solvent is dried before thevoid-containing structure is formed by the sedimentation and depositionof nano-sized pulverized sol particles in the solvent, formation of voidspaces may be inhibited to lower the void fraction considerably. On theother hand, when the coating, amount is too small, the risk of cissingdue to unevenness, variation in hydrophilicity and hydrophobicity, etc.on the surface of the base may increase.

After the gel pulverized product-containing solution is coated on thebase, the porous material precursor (coating film) may be subjected to adrying treatment. The purpose of the drying treatment is not only toremove the solvent in the porous material precursor (the solventcontained in the gel pulverized product-containing solution) but also toallow the sedimentation and deposition of the sol particles to occur toform a void-containing structure during the drying treatment, forexample. The temperature of the drying treatment is from 50° C. to 250°C., from 60° C. to 150° C., or from 70° C. to 130° C., for example, andthe time of the drying treatment is from 0.1 to 30 minutes, from 0.2 to10 minutes, or from 0.3 to 3 minutes, for example. In terms ofcontinuous productivity and realization of high void fraction, it ispreferable to set the temperature and the time of the drying treatmentlower and shorter, respectively, for example. If the conditions are toostringent, the following problem may arise, for example. That is, whenthe base is a resin film, for example, the base may extend in a dryingoven as the temperature approaches the glass-transition temperature ofthe base, so that a void-containing structure formed immediately afterthe coating may have defects such as cracks. On the other hand, when theconditions are too mild, the following problem may arise, for example.That is, the film may contain a residual solvent when it comes out ofthe drying oven, so that, if the film rubs against a roller in asubsequent step, defects in appearance such as scratches may be caused.

The diving treatment may be natural drying, heat drying, or drying underreduced pressure, for example. The drying method is not particularlylimited, and a commonly used heating unit can be used, for example.Examples of the heating unit include a hot air fan, a heating roller,and a fat-infrared heater. In particular, from the viewpoint ofperforming continuous production industrially heat drying is preferable.It is preferable to use a solvent having a low surface tension for thepurpose of inhibiting the shrinkage stress that may occur as the solventvolatizes during the drying process and inhibiting a crack phenomenon inthe void-containing layer (the silicone porous material) caused by theshrinkage stress. Examples of the solvent include, but are not limitedto, lower alcohols (typically, isopropyl alcohol [IPA]), hexane, andperfluorohexane.

The base is not limited to particular bases, and for example, a basemade of a thermoplastic resin, a base made of glass, an inorganic baseplate typified by silicon, a plastic formed of a thermosetting resin, anelement such as a semiconductor, or a carbon fiber-based materialtypified by carbon nanotube can be favorably used. The base, however, isby no means limited thereto. Examples of the form of the base include afilm and a plate. Examples of the thermoplastic resin includepolyethylene terephthalate (PET), acrylic resins, cellulose acetatepropionate (CAP), cycloolefin polymer (SOP), triacetylcellulose (TAC),polyethylene naphthalate (PEN), polyethylene (PE), and polypropylene(PP).

In the void-containing layer production method of the present, thebonding step is a step of chemically bonding the pulverized productscontained in the porous material precursor (coating film). By thebonding step, the three-dimensional structures of the pulverizedproducts in the porous material precursor are immobilized, for example.In the case of conventional immobilization by sintering, for example, atreatment at a high temperature of at least 200° C. is performed toinduce the dehydration condensation reaction of silanol groups and theformation of siloxane bonds. In the bonding step of the presentinvention, various additives that catalyze the above-describeddehydration condensation reaction are caused to react with each other.With this configuration, for example, when the base is a resin film, itis possible to continuously form and immobilize the void-containingstructure at a relatively low drying temperature of around 100° C., andwith a short treatment time of less than several minutes withoutdamaging the base.

The method for achieving the above-described chemical bonding is notparticularly limited, and can be determined as appropriate depending onthe type of the gel (e.g. silicon compound gel), for example. As aspecific example, the chemical bonding can be achieved by chemicallycrosslinking the pulverized products. Besides this, for example, wheninorganic particles such as titanium oxide particles are added to thepulverized products, the inorganic particles and the pulverized productsmay be chemically bonded by crosslinking. Furthermore, in the case ofcausing the pulverized products to carry a biocatalyst such as anenzyme, a site of the catalyst other than the catalytic site may bechemically crosslinked with the pulverized products. Therefore, thepresent invention is not only applicable to a void-containing layerformed by sol particles bonded to each other, but the applicable rangeof the present invention can be expanded to an organic-inorganic hybridvoid-containing layer and a host-guest void-containing layer, forexample. It is to be noted, however, that the applicable range of thepresent invention is not limited thereto.

Depending on the type of the gel pulverized product (e.g. siliconcompound gel), the bonding step can be carried out by causing a chemicalreaction in the presence of a catalyst, for example. The chemicalreaction in the present invention preferably is a reaction utilizing adehydration condensation reaction of residual silanol groups containedin the pulverized products of the silicon compound gel. By promoting thereaction between the hydroxyl groups in the silanol groups by thecatalyst, the void-containing structure can be cured in a short time, sothat continuous film formation becomes possible. Examples of thecatalyst include, but are not limited to, base catalysts such aspotassium hydroxide, sodium hydroxide, and ammonium hydroxide and acidcatalysts such as a hydrochloric acid, an acetic acid, and an oxalicacid. As a catalyst to be used in the dehydration condensation reaction,a base catalyst is particularly preferable. Also, catalysts that exhibitcatalytic activity when irradiated with light (e.g., ultraviolet rays),such as photoacid generation catalysts and photobase generationcatalysts can be used preferably. The photoacid generation catalysts andphotobase generation catalysts are not particularly limited, and are asdescribed above, for example. For example, it is preferable to add thecatalyst to a sol particle solution containing the pulverized productsimmediately before coating the sot particle solution as described above,or to use the catalyst in the form of a mixture with a solvent, forexample. The mixture may be, for example, a coating solution, obtainedby adding the catalyst directly to and dissolving the catalyst in thesol particle solution, a solution obtained by dissolving the catalyst ina solvent, or a dispersion obtained by dispersing the catalyst in asolvent. The solvent is not particularly limited, and examples thereofinclude water and buffer solutions, as described above.

Furthermore, for example, a crosslinking assisting, agent for indirectlybonding the pulverized products of the gel may be further added to thegel-containing solution of the present invention. This crosslinkingassisting agent enters the spaces between the respective particles (thepulverized products), where it interacts with or bonds to the particles.This allows the particles somewhat apart from each other to be bonded toeach other. As a result, it becomes possible to efficiently improve thestrength. The crosslinking assisting agent preferably is amulti-crosslinking silane monomer. Specifically, the multi-crosslinkingsilane monomer may have at least two and at most three alkoxysilylgroups, the chain length between the alkoxysilyl groups may be at leastone and at most ten carbon atoms, and the multi-crosslinking silanemonomer may contain an element other than carbon, for example. Examplesof the crosslinking assisting agent include bis(trimethoxysilyl)ethane,bis(triethaysilyl)ethane, bis(trimethoxysilyl)methane,bis(triethoxysilyl)methane, bis(triethoxysilyl)propane,bis(trimethoxysilyl)propane, bis(triethoxysilyl)butane,bis(trimetboxysilyl)butane, bis(triethoxysilyl)pentane,bis(trimethoxysilyl)pentane, bis(triethoxysilyl)hexane,bis(trimethoxysilyl)hexane,bis(trimethoxysilyl)-N-butyl-N-propyl-ethane-1,2-diamine,tris-(3-trimethoxysilylpropyl)isocyanurate, andtris-(3-triethoxysilylpropyl)isocyanurate. The amount of thecrosslinking assisting agent to be added is not particularly limited,and is, for example, in the range from 0.01 wt % to 20 wt %, from 0.05wt % to 15 wt %, or from 0.1 wt % to 10 wt % relative to the weight ofthe pulverized products of the silicon compound.

The chemical reaction in the presence of the catalyst can be caused by,for example: subjecting the coating film containing the catalyst or thecatalyst generator previously added to the gel pulverizedproduct-containing solution to light irradiation or heating; subjectingthe coating film to light irradiation or beating after spraying thecatalyst over the coating film; or subjecting the coating film to lightirradiation or heating while spraying the catalyst or the catalystgenerator over the coating film. When the catalyst is a photoactivecatalyst, the silicone porous material can be formed by chemicallybonding the microporous particles to each other by light irradiation.When the catalyst is a thermoactive catalyst, the silicone porousmaterial can be formed by chemically bonding the microporous particlesto each other by heating. The irradiation dose (energy) in the aboveirradiation is not limited to particular amounts and is, for example,from 200 to 800 mJ/cm², from 250 to 600 mJ/cm², or from 300 to 400mJ/cm², in terms of light at a wavelength of 360 nm. The accumulatedamount of light preferably is 200 mJ/cm² or more, from the viewpoint ofpreventing the problem in that, owing to insufficient irradiation dose,degradation of the catalyst generator by light absorption may notproceed sufficiently, so that the catalyst generator cannot exhibit itseffect sufficiently. The accumulated amount of light preferably is 800mJ/cm² or less, from the viewpoint of preventing damage to the basedisposed under the void-containing layer so as to prevent the formationof heat-wrinkles. The wavelength of light in the irradiation is notlimited to particular wavelengths and is, for example, from 200 to 500nm or from 300 to 450 nm. The irradiation time in the irradiation is notlimited to particular times and is, for example, from 0.1 to 30 minutes,from 0.2 to 10 minutes, or from 0.3 to 3 minutes. The conditions for theheat treatment are not limited to particular conditions. The heatingtemperature is from 50° C. to 250° C., from 60° C. to 150° C., or from70° C. to 130° C., for example, and the heating time is from 0.1 to 30minutes, from 0.2 to 10 minutes, or from 0.3 to 3 minutes, for example.It is preferable to use, for example, a solvent having a low surfacetension for the purpose of inhibiting the shrinkage stress that mayoccur as the solvent volatizes during the drying process and inhibitinga crack phenomenon in the void-containing layer caused by the shrinkagestress. Examples of the solvent include, but are not limited to, loweralcohols typically, isopropyl alcohol (IPA), hexane, andperfluorohexane.

The void-containing layer (e.g., silicone porous material) can beproduced in the above-described manner. The void-containing layerproduction method of the present invention, however, is not limitedthereto. The void-containing layer of the present invention, which is asilicone porous material, may be referred to as a “silicone porousmaterial of the present invention” in the description below.

In the production of the laminate of the present invention, apressure-sensitive adhesive/adhesive layer is further formed on thevoid-containing layer of the present invention (the pressure-sensitiveadhesive/adhesive layer forming step). Specifically, thepressure-sensitive adhesive/adhesive layer may be formed by applying(coating) a pressure-sensitive adhesive or an adhesive to thevoid-containing layer of the present invention, for example.Alternatively, the pressure-sensitive adhesive/adhesive layer may beformed on the void-containing layer of the present invention byadhering, e.g., an adhesive tape including a base and thepressure-sensitive adhesive/adhesive layer laminated on the base to thevoid-containing layer with the pressure-sensitive adhesive/adhesivelayer side of the adhesive tape facing the void-containing layer. Inthis case, the base of the adhesive tape may be left on the adhesivetape or may be peeled off from the pressure-sensitive adhesive/adhesivelayer. In particular, as described above, by peeling the base to form a(baseless) void-containing layer-containing pressure-sensitiveadhesive/adhesive sheet having no base, the thickness of the sheet canbe significantly reduced and the increase in the thickness of the deviceor the like can be prevented. In the present invention, the terms“pressure-sensitive adhesive” and “pressure-sensitive adhesive layer”respectively refer to an agent and a layer that adhere a substance in apeelable manner, for example. In the present invention, the terms“adhesive” and “adhesive layer” respectively refer to an agent and alayer that adhere a substance in a non-peelable manner, for example. Itis to be noted, however, that, in the present invention, the“pressure-sensitive adhesive” and the “adhesive” are not always clearlydistinguishable from each other, and also, the “pressure-sensitiveadhesive layer” and the “adhesive layer” are not always clearlydistinguishable from each other. In the present invention, apressure-sensitive adhesive or an adhesive for forming thepressure-sensitive adhesive/adhesive layer is not particularly limited,and a commonly used pressure-sensitive adhesive or adhesive can be used,for example. Examples of the pressure-sensitive adhesive and theadhesive include: polymer adhesives such as acrylic adhesives, vinylalcohol adhesives, silicone adhesives, polyester adhesives, polyurethaneadhesives, and polyether adhesives; and rubber adhesives. Further, thepressure-sensitive adhesive and the adhesive may be an adhesive composedof a water-soluble crosslinking agent of a vinyl alcohol polymer such asglutaraldehyde, melamine, or an oxalic acid. Examples of thepressure-sensitive adhesive include those described above. Only one typeof pressure-sensitive adhesive or adhesive may be used, or two or moretypes of pressure-sensitive adhesives or adhesives may be used incombination (e.g., they may be mixed together or may be laminated). Asdescribed above, the void-containing layer can be protected fromphysical damage (particularly abrasion) by the pressure-sensitiveadhesive/adhesive layer. It is preferable that the pressure-sensitiveadhesive/adhesive layer have excellent pressure resistance so that thevoid-containing, layer does not collapse even when used as a (baseless)void-containing layer-containing pressure-sensitive adhesive/adhesivesheet having no base, however, is not limited thereto. The thickness ofthe pressure-sensitive adhesive/adhesive layer is not particularlylimited, and is, for example, from 0.1 to 100 μm, from 5 to 50 μm, from10 to 30 μm, or from 12 to 25 μm.

The void-containing layer of the present invention obtained in thismanner may be further laminated on another film (layer) to form alaminated structure including the porous structure, for example. In thiscase, the respective components of the laminated structure may belaminated via the pressure-sensitive adhesive/adhesive layer(pressure-sensitive adhesive or an adhesive), for example.

The respective components may be laminated by continuous processingusing a long film (e.g., the so-called “roll-to-roll” process) in termsof efficiency, for example. When the base is a molded product, anelement, or the like, the components that have been subjected to batchprocessing may be laminated on the base.

Regarding the method for forming the laminate of the present inventionon a base (resin film), continuous processing steps will be describedbelow with reference to illustrative examples shown in FIGS. 1 to 3.FIG. 2 shows, after the film formation of the void-containing layer(silicone porous body), the steps of attaching a protective film to thethus-formed film and winding up the thus-obtained laminate. However, inthe case where the void-containing layer is laminated on anotherfunctional film, this may be achieved in the above-described manner, oralternatively, in the following manner: after performing coating anddrying for forming the functional film, the void-containing layer formedinto a film is adhered to the functional film immediately before beingwound-up. It should be noted that the film forming processes shown inFIGS. 1 to 3 are merely illustrative and do not limit the presentinvention by any means.

The base may be the resin film described above. In this case, thevoid-containing layer of the present invention is obtained by formingthe void-containing layer on the base. The void-containing layer of thepresent invention also is obtained by forming the void-containing layeron the base and then laminating the void-containing layer on the resinfilm described above in connection with the void-containing layer of thepresent invention.

The cross-sectional view of FIG. 1 schematically shows an example of aprocess of the method of producing the laminate of the present inventionin which the void-containing layer, the intermediate layer, and thepressure-sensitive adhesive/adhesive layer are laminated in this orderon the base (resin film). In FIG. 1, the method for forming thevoid-containing layer includes a coating step (1) of coating the solparticle solution 20″ of pulverized products of a gelled compound onto abase (resin film) 10 to form a coating film, a drying step (2) of dryingthe sol particle solution 20″ to form a dried coating film 20′, achemical treatment step (for example, a crosslinking step) (3) ofsubjecting the coating film 20′ to a chemical treatment (for example,crosslinking treatment) to form a void-containing layer 20, apressure-sensitive adhesive/adhesive layer coating step(pressure-sensitive adhesive/adhesive layer forming step) (4) of coatingthe pressure-sensitive adhesive/adhesive layer 30 onto thevoid-containing layer 20, and an intermediate layer forming step (5) offorming the intermediate layer 22 by reacting the void-containing layer20 with the pressure-sensitive adhesive/adhesive layer 30. The chemicaltreatment step (crosslinking step) (3) corresponds to the“void-containing layer forming step” in the laminated film productionmethod of the present invention. In FIG. 1, the intermediate layerforming step (5) (hereinafter sometimes referred to as an “aging step”)also serves as a step for improving the strength of the void-containinglayer 20 (crosslinking reaction step for causing a crosslinking reactioninside the void-containing layer 20), and after the intermediate layerforming step (5), the void-containing layer 20 is changed to avoid-containing layer 21 having improved strength. The presentinvention, however, is not limited thereto, and for example, thevoid-containing layer 20 may not be changed after the intermediate layerforming step (5). As described above, the pressure-sensitiveadhesive/adhesive layer forming step is not limited topressure-sensitive adhesive/adhesive layer coating, and may be, forexample, a pressure-sensitive adhesive tape including thepressure-sensitive adhesive/adhesive layer may be adhered to thevoid-containing layer 20, for example.

Through the above steps (1) to (5), as shown in FIG. 1, a laminated filmin which the void-containing layer 21, the intermediate layer 22, andthe pressure-sensitive adhesive/adhesive layer 30 are laminated in thisorder on the resin film 10 can be produced. The intermediate layerforming step (5), however, is not always necessary, and the producedlaminate of the present invention may not include the intermediatelayer. Furthermore, the laminated film production method of the presentinvention may or may not appropriately include steps other than theabove steps (1) to (5).

In the coating step (1), the method for coating the sol particlesolution 20″ is not particularly limited, and a commonly used coatingmethod can be employed. Examples of the coating method include a slotthe method, a reverse gravure coating method, a micro-gravure method(micro-gravure coating method), a dip method (dip coating method), aspin coating method, a brush coating method, a roller coating method, aflexography, a wire-bar coating method, a spray coating method, anextrusion coating method, a curtain coating method, and a reversecoating method. Among them, from the viewpoint of productivity,smoothness of a coating film, etc., the extrusion coating method, thecurtain coating method, the roller coating method, and the micro-gravurecoating method are preferable. The coating amount of the sol particlesolution 20″ is not particularly limited, and can be set as appropriateso that the void-containing layer 20 having, a suitable thickness isobtained, for example. The thickness of the void-containing layer 21 isnot particularly limited, and is as described above, for example.

In the drying step (2), the sol particle solution 20″ is dried (i.e., adispersion medium contained in the sol particle solution 20″ is removed)to form the coating film after drying (precursor of void-containinglayer) 20′. The conditions for the drying treatment are not particularlylimited, and may be as described above.

In the chemical treatment step (3), the coating film 20′ containing acatalyst or a catalyst generator (e.g., a photoactive catalyst, aphotocatalyst generator, a thermoactive catalyst, or a thermal catalystgenerator) added prior to the coating step is irradiated with light orheated, whereby the pulverized products in the coating film 20′ arechemically bonded (e.g., crosslinked) to each other. As a result, thevoid-containing layer 20 is formed. The conditions for the lightirradiation and heating in the chemical treatment step (3) are notparticularly limited, and may be as described above.

Further, the pressure-sensitive adhesive/adhesive layer coating step(pressure-sensitive adhesive/adhesive layer forming step) (4) andintermediate layer forming step (5) are not particularly limited, and asdescribed above.

FIG. 2 schematically shows an example of a slot the coating apparatusand the method for forming a void-containing layer using the same. WhileFIG. 2 is a sectional view, hatching is omitted for the sake of clarity.

As shown in FIG. 2, the respective steps in the method using thisapparatus are performed while conveying, a base 10 in one direction byrollers. The conveyance speed is not particularly limited, and is, forexample, from 1 to 100 m/min, from 3 to 50 m/min, or from 5 to 30 m/min.

First, while feeding and conveying the base 10 from a delivery roller101, a coating step (1) of coating a sol particle solution 20″ onto thebase 10 is performed on a coating roller 102. Subsequently, in an ovenzone 110, a drying step (2) is performed. In the coating apparatus shownin FIG. 2, a pre-drying step is performed after the coating step (1) andprior to the drying step (2). The pre-drying step can be performed atroom temperature without heating. In the drying step (2), heating units111 are used. As the heating unit 111, a hot air fan, a heating roll, afar-infrared heater, or the like can be used as appropriate, asdescribed above. Also, for example, the drying step (2) may be dividedinto two or more steps, and the drying temperatures in the respectivesteps may be set so that the diving temperature in the first stepincreases toward the step(s) subsequent thereto.

After the drying step (2), a chemical treatment step (3) is performed ina chemical treatment zone 120. In the chemical treatment step (3), whena coating film 20′ after being dried contains a photoactive catalyst,for example, the coating film 20′ is irradiated with light emitted fromlamps (light irradiation units) 121 disposed above and below the base10. On the other hand, when the coating film 20′ after being driedcontains a thermoactive catalyst, for example, hot air fans (heatingunits) are used instead of the lamps (light irradiation units) 121, andthe base 10 is heated using the hot air fans 121 disposed above andbelow the base 10. By this crosslinking treatment, pulverized productsin the coating film 20′ are chemically bonded to each other, whereby avoid-containing layer 20 is cured and strengthened. Although thechemical treatment step (3) is performed after the drying step (2) inthe present example, the timing at which chemical bonding of thepulverized products is caused in the production method of the presentinvention is not particularly limited, as described above. For example,as described above, the drying step (2) may also serve as the chemicaltreatment step (3). Further, even in the case where the chemical bondinghas occurred in the drying step (2), the chemical treatment step (3)further may be performed to make the chemical bonds between thepulverized products still stronger. Furthermore, the chemical binding ofthe pulverized products may occur in the steps (e.g., the pre-dryingstep, the coating step (1), and a step of preparing the coatingsolution) prior to the drying step (2).

After the chemical treatment step (3), the pressure-sensitiveadhesive/adhesive layer coating step (pressure-sensitiveadhesive/adhesive layer forming step) (4) of applying (coating) apressure-sensitive adhesive or an adhesive to a void-containing layer 20to form a pressure-sensitive adhesive/adhesive layer 30 is performed inthe pressure-sensitive adhesive/adhesive layer coating zone 130 a usingpressure-sensitive adhesive/adhesive layer coating units 131 a. Asdescribed above, instead of applying (coating) the pressure-sensitiveadhesive or the adhesive, an adhesive tape including thepressure-sensitive adhesive/adhesive layer 30 may be adhered (attached)to the void-containing layer 20, for example.

Further, an intermediate layer forming step (aging step) (5) isperformed in the intermediate layer forming zone (aging zone) 130 toform an intermediate layer 22 by reacting the void-containing layer 20with the pressure-sensitive adhesive/adhesive layer 30. In this step,the void-containing layer 20 undergoes an internal crosslinking reactionand turns into a void-containing layer 21 with an improved strength, asdescribed above. The intermediate layer forming step (aging step) (5)may be performed, for example, by heating the void-containing layer 20and the pressure-sensitive adhesive/adhesive layer 30 using hot air fans(heating units) 131 disposed above and below the base 10. The heatingtemperature, time, and the like are not particularly limited, and are,for example, as described above.

Then, after the intermediate layer forming step (aging step) (5), alaminate obtained by forming the void-containing layer 21 on the base 10is wound up by the winding roller 105. In FIG. 2, the void-containinglayer 21 in the laminate is protected by being covered with a protectingsheet fed by a roller 106. Instead of the protecting sheet, anotherlayer formed of long film may be laminated on the void-containing layer21.

FIG. 3 schematically shows an example of a coating apparatus for amicro-gravure method (micro-gravure coating method) and the method forforming a void-containing layer using the same. While FIG. 3 is asectional view, hatching is omitted for the sake of clarity.

As shown in FIG. 3, the respective steps in the method using thisapparatus are performed while conveying a base 10 in one direction byrollers, as in the example shown in FIG. 2. The conveyance speed is notparticularly limited, and is, for example, from 1 to 100 mi min, from 3to 50 m/min, or from 5 to 30 m/min.

First, while feeding and conveying the base 10 from a delivery roller201, a coating step (1) of coating a sol particle solution 20″ of thepresent invention onto the base 10 is performed. As shown in FIG. 3, thesol particle solution 20″ is coated using a solution reservoir 202, adoctor (doctor hide) 203, and a micro-gravure coater 204. Specifically,the sol particle solution 20″ in the solution reservoir 202 is caused tobe carried on the surface of the micro-gravure coater 204, and is thencoated on the surface of the base 10 with the micro-gravure coater 204while controlling, the thickness of the coating film of the sol particlesolution 20″ to a predetermined thickness with the doctor 203. It is tobe noted here that the micro-gravure coater 204 merely is an example ofa coating unit. The coating unit is not limited to the micro-gravurecoater 204, and any coating unit may be employed.

Next, a drying step (2) is performed. Specifically, as shown in FIG. 3,the base 10 having the sol particle solution 20″ coated thereon isconveyed to an oven zone 210. The sol particle solution 20″ is dried bybeing heated with heating units 211 disposed in the oven zone 210. Theheating units 211 may be the same as those in FIG. 2, for example. Thedrying step (2) may be divided into a plurality of steps by dividing theoven zone 210 into a plurality of sections, for example. The dryingtemperatures in the respective steps may be set so that the dryingtemperature in the first step increases toward the step(s) subsequentthereto. After the drying step (2), a chemical treatment step (3) isperformed in a chemical treatment zone 220. In the chemical treatmentstep (3), when a coating film 20′ after being dried contains aphotoactive catalyst, for example, the coating film 20′ is irradiatedwith light emitted from lamps (light irradiation units) 221 disposedabove and below the base 10. On the other hand, when the coating film20′ after being dried contains a thermoactive catalyst, for example, hotair fans (heating units) are used instead of the lamps (lightirradiation units) 221, and the base 10 is heated using the hot air fans221 disposed below the base 10. By this crosslinking treatment,pulverized products in the coating film 20′ are chemically bonded toeach other, whereby a void-containing layer 20 is formed.

After the chemical treatment step (3), the pressure-sensitiveadhesive/adhesive layer coating step (pressure-sensitiveadhesive/adhesive layer forming step) (4) of applying (coating) apressure-sensitive adhesive or an adhesive to a void-containing layer 20to form a pressure-sensitive adhesive/adhesive layer 30 is performed inthe pressure-sensitive adhesive/adhesive layer coating zone 230 a usingpressure-sensitive adhesive/adhesive layer coating units 231 a. Asdescribed above, instead of applying (coating) the pressure-sensitiveadhesive or the adhesive, an adhesive tape including thepressure-sensitive adhesive/adhesive layer 30 may be adhered (attached)to the void-containing layer 20, for example.

Further, an intermediate layer forming step (aging step) (5) isperformed in the intermediate layer forming zone (aging zone) 230 toform an intermediate layer 22 by reacting the void-containing layer 20with the pressure-sensitive adhesive/adhesive layer 30. In this step,the void-containing layer 20 turns into a void-containing layer 21 withan improved strength, as described above. The intermediate layer formingstep (aging step) (5) may be performed, for example, by heating thevoid-containing layer 20 and the pressure-sensitive adhesive/adhesivelayer 30 using hot air fans (heating units) 231 disposed above and belowthe base 10. The heating temperature, time, and the like are notparticularly limited, and are, for example, as described above.

Then, after the intermediate layer forming step (aging step) (5), alaminated film obtained by forming the void-containing layer 21 on thebase 10 is wound up by the winding roller 251. Thereafter, another layermay be laminated on the laminated film, for example. Further, before thelaminated film is wound up by the winding roller 251, another layer maybe laminated on the laminated film, for example.

EXAMPLES

Examples of the present invention will be described below. It is to benoted, however, that the present invention is by no means limited to thefollowing examples.

In the following reference examples, examples, and comparison examples,the number (relative usage amount) of each substance is the mass part(weight part) unless otherwise stated.

Reference Example 1: Production of Coating Solution for FormingVoid-Containing Layer

First, gelation of silicon compound (the following step (1)) and anaging step (the following step (2)) were performed to produce a gel(silicone porous material) having a porous structure. Thereafter, a gelform control step (3), a solvent replacement step (4), and a gelpulverization step (5) were further performed to obtain a coatingsolution for forming a void-containing; layer (sol particle solution).In the present reference example, the gel formation step (3) wasperformed as a different step from the step (1) as described below. Thepresent invention, however, is not limited thereto, and, for example,the gel form control step (3) may be performed in the step (1).

(1) Gelation of Silicon Compound

9.5 kg of a silicon compound precursor MTMS was dissolved in 0.22 kg ofDMSO. To the resultant mixture, 5 kg of 0.01 mol/L oxalic acid aqueoussolution was added. The resultant mixture was stirred at roomtemperature for 120 minutes, whereby MTMS was hydrolyzed to generatetris(hydroxy)methylsilane.

3.8 kg of ammonia water with an ammonia concentration of 28% and 2 kg ofpure water were added to 55 kg of DMSO. Thereafter, the above-describedmixture that had been subjected to the hydrolysis treatment was furtheradded thereto. The resultant mixture was stirred at room temperature fix60 minutes. Thereafter, the mixture after stirring for 60 minutes waspoured into a stainless container with a size of 30 cm in length×30 cmin width×5 cm in height and allowed to stand at room temperature tocause gelation of tris(hydroxy)methylsilane. Thus, a gelled siliconcompound was obtained.

(2) Aging Step

The gelled silicon compound obtained by the above gelation treatment wassubjected to an aging treatment by incubating it at 40° C. for 20 hours.Thus, a cuboid gel mass was obtained. The amount of DMSO (ahigh-boiling-point solvent with a boiling point of 130° C. or higher) tobe used in a raw material of this gel was about 83 wt % relative to thetotal amount of the raw material. Thus, it is obvious that this gelcontains 50 wt % or more of the high-boiling-point solvent with aboiling point of 130° C. or higher. The amount of MTMS (a monomer as astructural unit of the gel) to be used in a raw material of this gel wasabout 8 wt % relative to the total amount of the raw material. Thus, itis obvious that this gel contains 20 wt % or less of a solvent (methanolin this case) with a boiling point of less than 130° C. to be generatedin hydrolysis of the monomer (MTMS) that is a monomer as a structuralunit of the gel.

(3) Gel Form Control Step

Water, which is a replacement solvent, was introduced on the gelsynthesized in a stainless container with a size of 30 cm×30 cm×5 cm bythe steps (1) and (2). Then, a cutting blade of a cutting tool wasslowly inserted into the gel in the stainless container from the top tocut the gel into a cuboid each with a size of 1.5 cm×2 cm×5 cm.

(4) Solvent Replacement Step

Next, a solvent replacement step was performed as described in (4-1) to(4-3) below.

(4-1) After the “gel form control step (3)”, the gelled silicon compoundwas immersed in water 8 times the weight of the gelled silicon compound,and stirred slowly for 1 hour so that only water was convected. After 1hour, the water was replaced with water of the same weight and stirredfurther for 3 hours. Thereafter, the water was replaced again, and thenthe water was heated for 3 hours while slowly stirring at 60° C.

(4-2) After (4-1), the water was replaced with isopropyl alcohol 4 timesthe weight of the gelled silicon compound, and heated for 6 hours whilestirring at 60° C.

(4-3) After (4-2), the isopropyl alcohol was replaced with isobutylalcohol of the same weight and heated for 6 hours at 60° C., to replacethe solvent contained in the gelled silicon compound with isobutylalcohol. As described above, the gel for void-containing layerproduction of the present invention was produced.

(5) Gel Pulverization Step

The gel (gelled silicon compound) obtained after the concentrationmeasurement (concentration control) and concentration adjustment step(4) was subjected to a total of two stages of pulverization including afirst pulverization stage by continuous emulsification dispersion(Milder MDN304, manufactured by Pacific Machinery & Engineering Co.,Ltd) and second pulverization stage by high pressure media-lesspulverization (Star Burst HJP-25005, manufactured by Sugino MachineLimited). This pulverization treatment was performed in the followingmanner. First, 43.4 kg of the gel after being subjected to solventreplacement was prepared. This gel is a gelled silicon compoundcontaining a solvent. 26.2 kg of isobuyl alcohol was added to 43.4 kg ofthis gel after being subjected to solvent replacement, and the mixturewas then weighed. Thereafter, the mixture was subjected to a firstpulverization stage by closed-circuit pulverization for 20 minutes andthe second pulverization stage at a pulverization pressure of 100 MPa.Thus, a dispersion solution (sol particle solution) of nanometer-sizedparticles (pulverized products of the gel) in isobutyl alcohol wasobtained. Further, 224 g of methyl isobutyl ketone having 1.5% WPBG-266(trade name, manufactured by Wako Pure Chemical industries, Ltd.) wasadded to 3 kg of the sol particle solution, and 67.2 g of methylisobutyl ketone having 5 bis(trimethoxylyl)ethane (manufactured by TokyoChemical Industry Co., Ltd.) was added thereto, and then 31.8 g ofN,N-dimethylformamide was added and mixed, thereby obtaining a coatingsolution.

In the manner described above, the coating solution for formingvoid-containing layer (sol particle solution) of the present referenceexample (Reference Example 1) was produced. The peak pore diameter ofthe gel pulverized product (microporous particle) in the coatingsolution for forming void-containing layer (sol particle solution) wasmeasured by the method described above and found to be 12 nm.

Reference Example 2: Modification Reaction of Nanoparticles byFluoroalkyl Groups

0.27 g of IPA (isopropyl alcohol) was added to 0.06 g of 0.1 N (mol/L)HCl aqueous solution and then stirred, thereby obtaining a uniformsolution. To this solution, 10 g of MIBK-ST (trade name of NissanChemical Corporation: Si nanoparticle MIBK [methyl isobutyl ketone]dispersion) was added, and then 0.7 g oftrimethoxy(1H,1H,2H,2H-nonafluorohexyl)silane was added. The mixturethus obtained was heated and stirred at 60° C. for 1 hour to perform themodification reaction of the Si nanoparticles, thereby obtaining afluoroalkyl-group-modified Si nanoparticle dispersion (modifiednanoparticle dispersion).

Reference Example 3: Formation of Pressure-Sensitive Adhesive/AdhesiveLayer

The pressure-sensitive adhesive/adhesive layer of the present referenceexample, Reference Example 3) was formed by the following procedures (1)to (3).

(1) Preparation of Acrylic Polymer Solution

97 parts of butyl acrylate, 6 parts of N-acryloyl morpholine, 3 parts ofacrylic acid, 0.3 parts of 2-hydroxybutyl acrylate, and 0.1 parts byweight of 2,2′-azobisisobutyronitrile as a polymerization initiator wereput into a four-neck flask equipped with a stirring blade, athermometer, a nitrogen gas inlet tube, and a cooler together with 100 gof ethyl acetate. Subsequently, nitrogen gas was introduced while gentlystirring the contents of the four-neck flask to perform nitrogenreplacement. Thereafter, a polymerization reaction was performed for 8hours while maintaining the solution temperature in the four-neck flaskat about 55° C., thereby preparing an acrylic polymer solution.

(2) Preparation of Acrylic Pressure-Sensitive Adhesive Composition

To 100 parts of the solid content of the acrylic polymer solutionobtained in the (1) above, 0.2 parts of an isocyanate crosslinking agent(trade name: “Coronate L” manufactured by Nippon Polyurethane IndustryCo., Ltd., an adduct of trimethylolpropane with trilene diisocyanate),0.3 parts of benzoyl peroxide (trade name: “HYPER BMT” manufactured byNOF CORPORATION), and 0.2 parts of γ-glycidoxypropylmethoxysilane (tradename: “KBM-403” manufactured by Shin-Etsu Chemical Co., Ltd.) wereadded, thereby preparing an acrylic pressure-sensitive adhesivecomposition (acrylic pressure-sensitive adhesive solution),

(3) Formation of Pressure-Sensitive Adhesive/Adhesive Layer

The acrylic pressure-sensitive adhesive composition prepared in the (2)above was coated onto one side of a silicone-treated polyethyleneterephthalate (PET) film (manufactured by Mitsubishi Chemical PolyesterFilm Corporation, thickness: 38 μm) so that the thickness of thepressure-sensitive adhesive layer after being dried achieves 10 μm, andthe coated acrylic pressure-sensitive adhesive composition was dried at150° C. for 3 minutes, thereby forming a pressure-sensitive adhesivelayer (pressure-sensitive adhesive/adhesive layer). The storage elasticmodulus G′ of the pressure-sensitive adhesive layer (pressure-sensitiveadhesive/adhesive layer) at 23° C. was 1.3×10⁵.

Reference Example 4: Formation of Pressure-Sensitive Adhesive/AdhesiveLayer

The pressure-sensitive adhesive/adhesive layer of the present referenceexample (Reference Example 4) was formed by the following procedures (1)to (3).

(1) Preparation of Acrylic Polymer Solution

97 parts of butyl acrylate, 3 parts of acrylic acid, 1 part of2-hydroxyethyl acrylate, and 0.1 parts of 2,2′-azobisisobutyronitrile asa polymerization initiator were put into a four-neck flask equipped witha stirring blade, a thermometer, a nitrogen gas inlet tube, and a coolertogether with 100 g of ethyl acetate. Subsequently, nitrogen gas wasintroduced while gently string the contents of the four-neck flask toperform nitrogen replacement. Thereafter, a polymerization reaction wasperformed for 8 hours while maintaining the solution temperature in thefour-neck flask at about 55° C., thereby preparing an acrylic polymersolution.

(2) Preparation of Acrylic Pressure-Sensitive Adhesive Composition

To 100 parts of the solid content of the acrylic polymer solutionobtained in the (1) above, 0.5 parts of an isocyanate crosslinking agent(trade name: “Coronate L” manufactured by Nippon Polyurethane IndustryCo., Ltd., an adduct of trimethylolpropane with trilene diisocyanate),0.2 parts of benzoyl peroxide (trade name: “NYPER BMT” manufactured byNOF CORPORATION), and 0.2 parts of γ-glycidoxypropyhnethoxysilane (tradename: “KBM-403” manufactured by Shin-Etsu Chemical Co., Ltd.) wereadded, thereby preparing an acrylic pressure-sensitive adhesivecomposition solution.

(3) Formation of Pressure-Sensitive Adhesive/Adhesive Layer

The acrylic pressure-sensitive adhesive composition solution prepared inthe (2) above was coated onto one side of a silicone-treatedpolyethylene terephthalate (PET) film (manufactured by MitsubishiChemical Polyester Film Corporation, thickness: 38 μm) so that thethickness of the pressure-sensitive adhesive layer after drying achieves20 μm, and the coated acrylic pressure-sensitive adhesive compositionwas dried at 150° C. for 3 minutes, thereby forming a pressure-sensitiveadhesive layer (pressure-sensitive adhesive/adhesive layer). The storageelastic modulus G′ of the pressure-sensitive adhesive layer(pressure-sensitive adhesive/adhesive layer) at 23° C. was 1.1×10⁵.

Reference Example 5: Formation of Pressure-Sensitive Adhesive/AdhesiveLayer

The pressure-sensitive adhesive/adhesive layer of the present referenceexample (Reference Example 5) was formed by the following procedures (1)to (3).

(1) Preparation of Acrylic Polymer Solution

77 parts of butyl acrylate, 20 parts of phenoxyethyl acrylate, 2 partsof N-vinyl-2-pyrrolidone, 0.5 parts of acrylic acid, 0.5 parts of4-hydroxybutyl acrylate, and 0.1 parts of 2,2′-azobisisobutyronitrile asa polymerization initiator were put into a four-neck flask equipped witha stirring blade, a thermometer, a nitrogen gas inlet tube, and a coolertogether with 100 parts of ethyl acetate. Subsequently, nitrogen gas wasintroduced while gently stilling the contents of the four-neck flask toperform nitrogen replacement. Thereafter, a polymerization reaction wasperformed for 8 hours while maintaining the solution temperature in thefour-neck flask at about 55° C., thereby preparing an acrylic polymersolution.

(2) Preparation of Acrylic Pressure-Sensitive Adhesive Composition

To 100 parts of the solid content of the acrylic polymer solutionobtained in the (1) above, 0.1 parts of an isocyanate crosslinking agent(trade name: “TAKENATE D160N” manufactured by Mitsui Chemicals, Inc.,trimethylolpropane hexamethylene diisocyanate), 0.3 parts of benzoylperoxide (trade name: “HYPER BMT” manufactured by NOF CORPORATION), and0.2 parts of γ-glycidoxypropylmethoxysilane (trade name: “KBM-403”manufactured by Shin-Etsu Chemical Co., Ltd.) were added, therebypreparing an acrylic pressure-sensitive adhesive composition solution.

(3) Formation of Pressure-Sensitive Adhesive/Adhesive Layer

The acrylic pressure-sensitive adhesive composition solution prepared inthe (2) above was coated onto one side of a polyethylene terephthalate(PET) film (separator film: manufactured by Mitsubishi ChemicalPolyester Film Corporation, trade name “MRF38”) that has been treatedwith a silicone separator, and the coated acrylic pressure-sensitiveadhesive composition solution was dried at 150° C. for 3 minutes,thereby forming a pressure sensitive adhesive layer (pressure-sensitiveadhesive/adhesive layer) having a thickness of 20 μm on the surface ofthe separator film. The storage elastic modulus G′ of thepressure-sensitive adhesive layer (pressure-sensitive adhesive/adhesivelayer) at 23° C. was 1.1×10⁵.

Reference Example 6: Formation of Pressure-Sensitive Adhesive/AdhesiveLayer

The pressure-sensitive adhesive/adhesive layer of the present referenceexample (Reference Example 6) was formed by the following procedures (1)to (3).

(1) Preparation of Prepolymer Composition

0.035 parts of photopolymerization initiator (trade name: “Irgacure184”, BASF) and 0.035 parts of photopolymerization initiator (tradename: “Irgacure 651”, BASF) were added to a monomer mixture composed of68 parts of 2-ethylhexyl acrylate, 14.5 parts of N-vinyl-2-pyrrolidone,and 17.5 parts of 2-hydroxyethyl acrylate, and then the resultant wasirradiated with ultraviolet rays until the viscosity (BH viscosity meterNo. 5 rotor, 10 rpm, measurement temperature 30° C.) reached about 2.0Pa·s, thereby obtaining a prepolymer composition in which parts of themonomer components were polymerized.

(2) Preparation of Acrylic Pressure-Sensitive Adhesive Composition

To the prepolymer composition obtained in the (1) above, 0.150 parts ofhexanediol diacrylate (HDDA) and 0.3 parts of silane coupling agent(trade name “KBM-403”, Shin-Etsu Chemical Co., Ltd.) were added andmixed, thereby obtaining an acrylic pressure-sensitive adhesivecomposition.

(3) Formation of Pressure-Sensitive Adhesive/Adhesive Layer

The acrylic pressure-sensitive adhesive composition prepared in the (2)above was coated onto one side of a silicone-treated polyethyleneterephthalate (PET) film (manufactured by Mitsubishi Chemical PolyesterFilm Corporation, thickness: 50 μm) so that the thickness of thepressure-sensitive adhesive layer after being dried achieves 25 μm, andfurther, a silicone-treated polyethylene terephthalate (PET) film(manufactured by Mitsubishi Chemical Polyester Film Corporation,thickness: 38 μm) was provided on the coating layer to cover the coatinglayer to block oxygen. Then, the laminate was irradiated withultraviolet rays at the illuminance of 5 mW/cm2 for 300 seconds from theupper surface (MRF38 side) thereof using a black light (manufactured byTOSHIBA CORPORATION). Further, a drying treatment was performed with adryer at 90° C. for 2 minutes to volatilize the remaining monomers toform a pressure-sensitive adhesive layer (pressure-sensitiveadhesive/adhesive layer). The storage elastic modulus G′ of thepressure-sensitive adhesive layer (pressure-sensitive adhesive/adhesivelayer) at 23° C. was 1.1×10⁵.

Example 1

0.06 g of the modified nanoparticle dispersion obtained in ReferenceExample 2 was added to 3 g of the coating solution for forming avoid-containing layer prepared in Reference Example 1, and then theresultant was coated onto an acrylic base and the coated solution wasdried, thereby forming a void-containing layer having a thickness ofabout 800 nm (void fraction: 59 vol %). Then the resultant wasirradiated with UV (300 mJ) from the surface of the void-containinglayer. Thereafter, the pressure-sensitive adhesive/adhesive layer(pressure-sensitive adhesive) having a thickness of 10 μm obtained inReference Example 3 was adhered to the surface of the void-containinglayer, thereby producing a laminate of the void-containing layer and thepressure-sensitive adhesive/adhesive layer.

Further, the laminate of the present example produced as described abovewas put into an oven at 85° C. and at 85% RH to perform aheat/humidification durability test for 130 hours. The degree of fillingof the voids in the void-containing layer after the heat/humidificationdurability test was examined with SEM, and the void remaining ratio wascalculated. The results are shown in Table 1.

Example 2

The void-containing layer and laminate of the present example wereproduced by performing the same operations as in Example 1 except thatthe pressure-sensitive adhesive obtained in Reference Example 4 was usedinstead of the pressure-sensitive adhesive of Reference Example 3.Further, the heat/humidification durability test was conducted in thesame manner as in Example 1, and the void remaining, ratio wascalculated. The results are shown in Table 1.

Example 3

The void-containing layer and laminate of the present example wereproduced by performing the same operations as in Example 1 except thatthe pressure-sensitive adhesive obtained in Reference Example 5 was usedinstead of the pressure-sensitive adhesive of Reference Example 3.Further, the heat/humidification durability test was conducted inuresame manner as in Example 1, and the void remaining ratio wascalculated. The results are shown in Table 1.

Example 4

The void-containing layer and laminate of the present example wereproduced by performing the same operations as in Example 1 except thatthe pressure-sensitive adhesive obtained in Reference Example 6 was usedinstead of the pressure-sensitive adhesive of Reference Example 3.Further, the heat/humidification durability test was conducted in thesame manner as in Example 1, and the void remaining ratio vascalculated. The results are shown in Table 1.

Comparative Example 1

The void-containing layer and laminate of the present comparativeexample were produced by performing the same operations as in Example 1except that, instead of the modified nanoparticle dispersion obtained inReference Example 2, the same amount of MIBK-ST (trade name of NissanChemical Corporation: Si nanoparticle MIBK [methyl isobutyl ketone]dispersion) was used as it was without being modified with a fluoroalkylgroup. Further, the heat/humidification durability test was conducted inthe same manner as in Example 1, and the void remaining ratio wascalculated. The results are shown in Table 1.

Comparative Example 2

The void-containing layer and laminate of the present comparativeexample were produced by performing the same operations as in Example 1except that, instead of the modified nanoparticle dispersion obtained inReference Example 2, only 0.01 g oftrimethoxy(1H,1H,2H,2H-nonfluorohexyl)silane was added (Si nanoparticleswere not added). Further, the heat/humidification durability test wasconducted in the same manner as in Example 1, and the void remainingratio was calculated. The results are shown in Table 1.

Then, the pressure-sensitive adhesive force of each of the laminatesobtained in Examples 1 to 4 and Comparative Examples 1 to 2 was measuredby the above-described measurement method. The results are also shown inTable 1.

TABLE 1 Comp. Comp. Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 1 Ex. 2 Void fraction 59%  59%  59%  59%  59%  59% (vol %) Refractive 1.18 1.18 1.18 1.181.18 1.18 index of void-containing layer Voidremaining >80% >80% >55% >80% >10% >10% ratio after durability testPressure- 1.8N/ 1.5N/ 1.9N/ 1.6N/ 1.6N/ 1.3N/ sensitive 25 mm 25 mm 25mm 25 mm 25 mm 25 mm adhesive force Measurement method of void remainingratio:The void portion was binarized and calculated, from the SEM imageafter the durability test.

As shown in Table 1, the laminates using the void-containing layers ofExamples 1 to 4 achieve the reduction of a tendency of apressure-sensitive adhesive (pressure-sensitive adhesive/adhesive layer)to penetrate into voids, and the void remaining ratio of the voidcontaining layer after the durability test was high. On the other hand,in both Comparative Example 1 in which nanoparticles were used as theywere without being modified with fluoroalkyl groups and ComparativeExample 2 in which only 0.01 g oftrimethoxy(1H,1H,2H,2H-nonafluorohexyl)silane was added without usingnanoparticles, a pressure-sensitive adhesive (pressure-sensitiveadhesive/adhesive layer) permeated into the voids of void-containinglayer, and the void remaining ratio of the void-containing layer afterthe durability test was low.

FIG. 4 shows a cross-sectional photograph (cross-sectional SEM image) ofthe laminate of Example 1 by a scanning electron microscope (SEM). FIG.5 shows a cross-sectional photograph (cross-sectional SEM image) of thelaminate of Comparative Example 1, and FIG. 6 shows a cross-sectionalphotograph (cross-sectional SEM image) of the laminate of ComparativeExample 2. The cross-sectional SEM images of FIGS. 4 to 6 are allcross-sectional SEM images after the durability test. As shown in thephotograph of FIG. 4, in the laminate of Example 1, the void remainingratio of the void-containing layer after the durability test was high.In contrast, in the laminates of Comparative Examples 1 and 2, as shownin the photographs of FIGS. 5 and 6, a pressure-sensitive adhesive(pressure-sensitive adhesive/adhesive layer) permeated into the voids ofthe void-containing layer, and the void remaining ratio of thevoid-containing layer after the durability test was low.

INDUSTRIAL APPLICABILITY

As described above, the present invention can provide a void-containinglayer in which a pressure-sensitive adhesive or an adhesive is lesslikely penetrated into voids, can also provide a laminate including thevoid-containing layer, a method for producing the void-containing layer,and an optical member and an optical apparatus including thevoid-containing layer. The application of the present invention is notparticularly limited. For example, the optical apparatus of the presentinvention is not particularly limited, and may be an image displaydevice, an illumination device, or the like. Examples of the imagedisplay device include a liquid crystal display, an organic EL display,and a micro LED display. The illumination device may be, for example, anorganic EL illumination, or the like. Further, the application of thevoid-containing layer and the laminate of the present invention is notlimited to the optical member and the optical apparatus of the presentinvention, and can be used in a wide range of applications.

This application claims priority from Japanese Patent Application No.2017-190747 filed on Sep. 29, 2017. The entire subject matter of theJapanese Patent Application is incorporated herein by reference.

REFERENCE SIGNS LIST

-   10: base-   20: void-containing layer-   20′: coating film (after drying)-   20″: sol particle solution-   21: void-containing layer with improved strength-   22: intermediate layer-   30: pressure-sensitive adhesive/adhesive layer-   101: delivery roller-   102: coating roller-   110: oven zone-   111: hot air fan (heating unit)-   120: chemical treatment zone-   121: lamp (light irradiation unit) or hot air fan (heating unit)-   130 a: pressure-sensitive adhesive/adhesive layer coating zone-   130: intermediate layer forming zone-   131 a: pressure-sensitive adhesive/adhesive layer coating unit-   131: hot air fan (heating unit)-   105: winding roller-   106: roller-   201: delivery roller-   202: solution reservoir-   203: doctor (doctor knife)-   204: micro-gravure coater-   210: oven zone-   211: heating unit-   220: chemical treatment zone-   221: light irradiation unit or heating unit-   230 a: pressure-sensitive adhesive/adhesive layer coating zone-   230: intermediate layer forming zone-   231 a: pressure-sensitive adhesive/adhesive layer coating unit-   231: hot air fan (heating unit)-   251: winding roller

The invention claimed is:
 1. A void-containing layer having a voidfraction of 35 vol % or more, and a peak void diameter of 5 nm or moreand 50 nm or less, comprising: a porous layer comprising a plurality ofmicroporous particles of a gel pulverized product chemically bonded toeach other and having voids between the microporous particles whereinthe voids are interconnected with each other, and wherein the gelpulverized product includes at least one element selected from the groupconsisting of Si, Mg, Al, Ti, Zn and Zr; and wherein voids on anoutermost surface of the porous layer are filled with silicananoparticles, surfaces of which being modified with a compound having asurface orientation, wherein the compound having the surface orientationis an alkoxysilane derivative, and the alkoxysilane derivative comprisesa fluoroalkyl group having 5 to 17 fluorine atoms.
 2. Thevoid-containing layer according to claim 1, wherein the void-containinglayer comprises 10 to 50 mass % of the silica nanoparticles relative tothe mass of a skeleton component of the void-containing layer whereinthe skeleton component comprises microporous particles of the gelpulverized product.
 3. An optical member comprising the void-containinglayer according to claim
 2. 4. A laminate obtained by directlylaminating the void-containing layer according to claim 1 to apressure-sensitive adhesive/adhesive layer.
 5. An optical membercomprising the laminate according to claim
 4. 6. An optical membercomprising the void-containing layer according to claim
 1. 7. An opticalapparatus comprising the optical member according to claim
 6. 8. Thevoid-containing layer according to claim 1, wherein the fluoroalkylgroup has 9 to 10 fluorine atoms.
 9. The void-containing layer accordingto claim 1, wherein the void-containing layer has a void fraction of 59vol % or more.